Home

Platestream 46 manual

1.
2. SERVICE MANUAL Processor Section Operation Safeguards 1 Do not spill liquids into the electrical compartment or on other electrical components Do not operate the processor if electrical components have been damaged 2 Disconnect electrical power before servicing the processor 3 Before handling photographic chemicals read the manufacturer s handling procedures including the material safety data sheets Chemicals used in processing are hazardous if handled carelessly Systems Transport When the leading edge of the plate exits the imager the processor transport system also starts Opposed rollers guides and belts will move the media through the activator and stabilizer racks dryer and into the receiver tray Heating The solution in the activator tank is heated by a blanket heater attached to the underside of the tank The heater energizes when power is applied to the processor providing that there is solution in contact with the working tank level sensor The solution temperature is maintained by a working tank temperature sensor Over temperature protection is provided for by means of a thermostat in the blanket heater The dryer heater energizes when imaging starts and de energizes a few seconds after the last plate falls into the receiver The dryer temperature is maintained at the set point by means of a sensor in the dryer chamber Over temperature protection is provided for by a thermostat in the heater ass
3. 64 Processor Mechanical Problems 66 Processor Sensor Problems 67 Processor Electrical Problems 68 Media Problems a oe t ted 71 Press Related 72 Wiring Di amp gratm uir 73 SERVICE MANUAL CHAPTER 1 GENERAL INFORMATION This Platesetter has been certified as a Class 1 laser product under the U Department of Health and Human Services DHHS Radiation Performance Standard This standard is in accordance with the Radiation Control for Health and Safety Act of 1968 A Class 1 certification means the Imager does not produce hazardous laser radiation Observe proper Electro Static Discharge ESD procedures at all times during maintenance of this equipment especially when servicing the RIP ESD can damage sensitive micro electronic circuitry leading to immediate failure or gradual degradation of performance over time Observing the fol lowing precautions will help to prevent ESD damage to components Always keep PCAs in anti static bags during transport or at any time when removed from the ma chine Never lay them down unprotected unless working at a static protected workstation Wear a ground strap attached to your wrist and to the frame of the machine Always keep ESD in mind when working on electronic equipment
4. L 2 P d a 2 Printware ASSY PROCESSOR PLATSTREAM 46 808155 001 REVISION E Sheet 3 of 5 PRINTWARE Confidential GROUND WIRE Z rintware ASSY PROCESSOR PLATESTREAM 46 808155 001 REVISION E Sheet 4 of 5 PRINTWARE Confidential IIS ID THIS SIDE SEE NOTE 2 808155 001 REVISION E PRINTWARE Confidential Sheet 5 of 5 Find Number 001 002 003 004 005 006 Quantity Component Used UD 9 Assembly Number 806710 001 Number 806775 001 900960 019 901090 001 806824 001 900268 005 901079 001 ASSY DRIVE SHAFT Revision E Component Description Parts List Page 1 of 1 SHAFT DRIVE GEAR WORM BEARING THRUST BEARING FLANGE MOD PULLEY TIMING BELT 1 5 PITCH PIN SPIRAL PRINTWARE Confidential Printware ASS Y DRIVE SHAFT 806710 001 REVISION E PRINTWARE Confidential Sheet I of I Find Number 001 002 003 004 005 006 007 008 Quantity Component Used 2 pb Assembly Number 806714 001 Number 900960 004 900271 004 900960 002 900582 007 900268 008 806770 001 900229 017 806729 001 ASSY DRYER DRIVE Revision F Component Description Parts List Page 1 of 1 BEARING ROLLER BELT TIMING 1 5 PITCH 100 GROOVES GEAR WORM SINGLE PIN DOWEL SST 1250 DIA X 625 LONG PULLEY TIMING BELT 1 5 PITCH SHAFT DRIVE BELT
5. SERVICE MANUAL Cleaning the Galvanometer Window Reversing Mirror Spherical Mirror and the Folding Mirror if Compressed Air Does Not Remove the Particles Spots 1 Soak a clean piece of webril wipe with acetone and very carefully and gently wipe the mirror surfaces that have particles attached to them Be sure that only the webril wipes comes in contact with mirror surface Wipe the mirror with a steady slow pace in one direction Use the same method on the galvanometer window Do not clean mirror surfaces or the galvanometer window surface unnecessarily If a surface is clean leave it alone The mirrors and the galvanometer window have thin fragile surface coatings that can be very easily rubbed off Once the surface is rubbed off the mirror is ruined and the entire marker assembly will have to be returned to Printware for repair If spots other than dust particles are present apply only enough pressure to remove these spots It is better to under clean than to over clean a mirror surface If the tissue becomes dirty use a new piece of tissue soaked with acetone 2 Examine each surface with a flashlight to ensure that the entire surface is clean 3 Reinstall the Marker lower cover Do not operate the Platesetter with the lower cover removed Lower the marker and close the top cover Print plates to determine if print quality has improved Marker Focus adjustment Procedure 1 At 1200 DPI image 12 long 4 pixel
6. NS FOUR PIECES AS REGID BOTTOM BRACKET WELDMENT e E E a TOP BRACKET WELDMENT ASSY SHROUD 806882 001 REVISION G Sheet of I PRINTWARE Confidential Find Number 001 002 003 004 005 006 007 009 010 011 012 013 014 015 016 017 018 019 020 021 022 023 024 025 025 026 026 029 030 031 032 033 034 035 036 037 038 039 040 041 042 043 Quantity Component Used OF N e N e e e N e N Rh e e A a gt CGN gt 2 22 Assembly Number 808155 001 ASSY PROCESSOR PLATESTREAM 46 Number 806743 001 806713 001 900960 005 806733 001 806824 001 900289 003 806786 001 807497 001 806710 001 806714 001 807494 001 806724 001 806727 001 807495 001 900289 004 806792 001 900338 001 900053 002 806715 001 900302 008 806769 001 600333 001 806731 001 807206 001 807328 001 807205 001 807327 001 806701 001 806702 001 806725 001 900338 002 806793 001 806794 001 900040 003 600330 001 806831 001 806704 001 806705 001 806788 001 806789 001 806790 001 523150 001 Revision G Component Description PANEL SUPPORT RACK ASSY CLUTCH SHAFT BEARING ROLLER BRACKET CLUTCH BEARING FLANGE MOD BUSHING GROMMET ASSY TEMP PROBE ACTIVATOR ASSY LEVEL SENSOR ASSY DRIVE SHAFT ASSY DRYER DRIVE SUPPORT UPPER DUCT RAIL RIGHT GUSSET RAI
7. CABLE Ji NU 1 BROWN E POWER SUPPLY BOX 2 3 x 7 332 803319 002 gt CABLE 803321001 4 YELLOW PRN GND 21 n asv 1 5 GREEN NC 3 RED POWER SUPPLY GND 2 BLUE PRN GND Ep S gt ORANGE DRAWER Ed 3 7 VIOLET NC 4 15 BLACK BLACK GND 3 s GRAY PRN OND 25 5 ORANGE 807046 001 YELLOW V 5 s WHITE NC 5 o FAN MOUNTS BLACK BLACK GND CONTROLLER PCA 1 BLACK PRN GND 24 5 FRONT OF POWER SUPPLY BLUE TV 7 1 BROWN PIX ENBL 6 15 ae BLACK GND 522980 001 127 RED PIX ENBL 25 A 2 ORANGE Dav E 13 ORANGE PIX CK 7 J4 BLACK GND 10 522980 002 1i YELLOW PIX CLK 1 RED 15 GREEN PRN DO 8 YELLOW CONTROLLER 16 BLUE PRN DO 27 BLUE SCHEMATIC PAGE 3 1 VIOLET PRN DI 5 ORANGE CONT INTERLOCK PWR 1 18 PRN DI BLACK CONT GND INTERLOCK ASSY IN 2 19 WHITE PRN y VENTFAN 324 Y x y 19 TO RIP ORANGE E NC 3 20 BLACK PRN 25 5 VENTFANRIN 806302 21 BROWN PRN D3 I Py DC POWER SUPPLY PAPE RED D3 30 901142 001 ALL FUSES CABLE 803312 003 23 ORANGE PRN D4 250V 15 RED 24 YELLOW PRN D47 31 0322 001 80528001 IR BLUE 12V 3 26 BLUE D5 32 45V FUSE YELLOW INIRF 2V PANEL 807220 RED BLACK GND 4 27 VIOLET PRN D6 14 INTRI BROWN PHOTODIODE s 28 GRAY D6 33 24V OPERATOR PANEL 55 BLACK GND 6 29 WHITE PRNEDT p CABLE 803312 003 c 807148 001 31 BR
8. O Q Q O 2 Once the plate has been imaged and processed measure the angle E see Figure I 8 Adjust roller pressure to eliminate transport skew as follows see Figure I 9 E Figure I 8 Checking for Transport Skew If angle E is gt 90 tighten the roller pressure on the s as i front operator end of the second pinch roller If angle E is lt 90 tighten the roller pressure on the rear end of the second pinch roller Imager Cover w Lever Marker oi Oss v L3 Guide A pins l Pinch Rollers sot Media path Guide B pins Load Knob Guide C2 pins Guide C1 pins Figure I 9 Location of the Pinch Rollers Image Skew Image skew is caused by the laser marker assembly being tilted relative to the capstan roller Image skew is present when the material is square but the image on the media is measurably skewed 1 Check for image skew by comparing the two di agonal image measurements Measure the distance from point C to point F see Figure I 10 and compare this to the distance from point D to point E If the two diagonal measurements are equal no image skew is present skip the remainder of this procedure and go on to the next section Scan Width and Linearity Adjustment 2 To correct image skew adjust the laser marker assembly position bolt Notify Printware s Cus tomer Service Department at 1 800 456 1400 be fore adjusting this bolt to avoid
9. Tighten the two 9 64 Allen cap screws After adjustment run two plates and check the second plate for skew Operator Side front of Platesetter T NOTE You must run two plates before checking the results as the first plate will have one cut made at the previous setting Figure 1 5 Checking Cutter Squareness 6 Continue adjusting cutter position and inspecting test plates until the plate is cut square Reattach the rear cover to the Imager unit 1 16 INSTALLATION GUIDE Transport Skew Transport skew results when the media is not feeding Leading Edge through the rollers perpendicular to the capstan roller Before making any other adjustments check the four edge guides to ensure they are securely in place Also check the adjustable guides toward the front of the Platesetter they should be flush with the media but not so tight that they cause the media to buckle as it moves If you are unsure of whether or not the media is being transported properly open the Platesetter top cover press the load key 5 on the Platesetter con trol panel Main Menu and watch the media Once you have determined that the edge guides are prop erly in place follow the procedure below to optimize transport skew UJ 1 To determine whether or not the image is square on the plate print eithera grid pattern or a solid pattern from the RIP D JE D N O O 9
10. 16 SERVICE MANUAL Cover G 2 Processor Capstan Roller Working Tanks d Cover E a Guide C2 pins 3 574 Guide D pins Guide F pins Media path E te L Processor exit Guide B pins 4 Si Et gov gt Replenishment Guide C1 pins 2 Pump Effluent Drain 7 Optional Effluent Tank gt Replenishment Tanks ActivatorRack lt TN y Dryer Belts y Dryer Drive Clutch Rack Drive Gear Drive Motor Belt Drive Shaft Worm Gear Figure S2 3 View of the Processor 17 SERVICE MANUAL Heater Element PROC Switch Drive R42 R43 Motor i C2 Processor PCA Screws Blower Figure S2 4 Right Side View of the PlateStream 46 Platesetter 18 SERVICE MANUAL 19 This page intentionally left blank SERVICE MANUAL CHAPTER 3 COMPONENT REPAIR AND REPLACEMENT Replacing Rollers Belts Motors and Cutter Overview This section provides the procedures for removing and reinstalling the following 20 rollers see Figure 52 2 Two feed rollers upper and lower Two pinch rollers left and right One capstan roller Two imager exit rollers upper and lower Thirteen processor rollers NOTES 1 When removing rollers label all spacers in terms of front or rear 1f any and which roller they were used with For the Platesetter to function correctly all spacers must be placed back in their original
11. 5 Install the new PCA in reverse order Replace front panel 35 SERVICE MANUAL This page intentionally left blank 36 SERVICE MANUAL Power Supply Assembly Location The Power Supply assembly is located underneath the Imager See Figure 54 1 The power supply provides all DC power within the Platesetter and also provides AC power The circuit breaker prevents high current from damaging the Platesetter electronics Components The power supply contains a PCA which is responsible for distributing the correct signals within the Platesetter The connectors and other items on the external portion of the power supply drawer are described below Power on off switch Circuit Breaker 20 amp Outlet incoming power connection Connector 11 engine stepper PCA Connector J4 controller microstepper fan Connector J5 interface and operator panel PCA s Replacing the Power Supply Assembly 1 Turn the Platesetter off and unplug Remove the rear panel 2 Disconnect the cables from the power supply Note the orientation of each cable 3 Access the power supply screws by opening the bottom front doors Remove power supply by unscrewing the nine screws and pull power supply out of the Platesetter from the rear 4 Install the new power supply in reverse order Replace the rear panel and close bottom front doors 37 SERVICE MANUAL Sensors The sensor Status menu indicates the current digital sta
12. Unplug the three pin connector labeled EXIT CAS from the optional film cassette sensor located on the left side of the processor Separate the Processor from the Imager by unbolting the four bolts located on the left side of the Processor that attach the Processor to the Imager Place the four sets of hardware in a plastic bag and tape to the inside front of the Imager Unplug the black power cord from the power supply located in the bottom rear on the Imager Bubble wrap the end of the cable and place inside the Processor Remove the wire tray located on the right side of the Platesetter Bubble wrap and place in accessory box 7 Package the Processor Close the top cover of the Processor Place two DESI PAK bags on the Processor crate Roll the Processor up the ramp onto the Processor crate b Attach the metal shipping brace to the inside bottom of the front with screws Place replenishment and optional effluent tanks underneath Processor c Support the Processor up off of the wheels by 1 Placing the 18 by 6 3 4 46 cm x 17 cm wood block with lip underneath the brace in the bottom front of the Processor The frame must rest on the foam 2 Placing the 18 by 6 3 4 46 cm x 17 cm wood block underneath the bottom back of the Processor The frame of the Processor must rest on the foam 3 Placing the two 24 by 6 3 4 61 cm x 17 cm wood blocks underneath the bottom sides of the Processor The frame
13. 7 10 Calling for nono 7 12 Appendix 2 Appendix B waa B 2 Appendix C Halftoning and C 2 GENERAL INFORMATION CHAPTER 1 GENERAL INFORMATION Introduction The Printware PlateStream 46 Platesetter is a compact high resolution digital Platesetter for a range of small format printing applications Plates are exposed using a patented laser imaging system and automatically processed Figure 1 1 illustrates a flowchart of the platemaking process The Platesetter is controlled by a Raster Image Processor RIP several different RIP options are available depending on the most common type of work to be done The system is driven by the host computer on which the operator composes the text and graphics to be imaged Once the print job has been composed on the host computer it is sent to the RIP where it is prepared for imaging The rasterized file is then sent to the Platesetter where the file is imaged onto a plate Figure 1 2 illus trates the basic system set up received the Feed Rollers The media is engage to pull the media pulled around the forward Capstan Roller 3 3 The laser light beam strikes and exposes selected areas of the CEN EN media 4 The plate is fed through Oncethe en
14. Gently roll out cart s from underneath the processor See figure 3 1 If necessary prepare the Activator and Stabilizer solutions in the plastic replenishment tanks following the manufacturer s instructions Remove probes from the replenishment tanks by unscrewing the white cap Fill the processor working tanks inside the Platesetter and the replenishment tanks with the proper chemistry Reinstall the probes into the replenishment tanks Make sure the activator tanks are filled with activator and the stabilizer tanks are filled with stabilizer Place cover E over processor working tanks Close the top cover Remove the probe and vinyl hose from the optional effluent tank Remove the optional effluent tank and empty it Be sure to dispose of or recycle the spent chemistry in accordance with local regulations Reinstall the probe and vinyl hose into the optional effluent tank Reinstall the optional effluent tank and close the tank cover Gently push the cart s under the processor and close the bottom front doors Imager Cover y Lever Load Knob PREPARING FOR OPERATION Dryer Cover G eroe Processor Guide A Capstan Roller Working Tanks pins Cover E Ben Se 22 Guide C2 pins Guide D pins m Di GE 2 Lo or gt se M sad L Processor exit 4 do Guide 1 pins Guide F pins Media path Guide B pins Activator Effluent Drain gt A P Option
15. Power Switch xS 24 60 cm Rear I O panel right clearance Supply Cassette E D 52 i 132 cm 24 60 front clearance Figure 1 1 Location of the Power Switch on the Platesetter 1 10 INSTALLATION GUIDE Loading Plate Material 1 Open the platesetter top cover Raise the marker by pulling the marker lever towards the front of the platesetter until the lever stops Lift up the marker gently 2 Pull out the load knob on the left side of the platesetter From inside of the platesetter adjust the two rear edge guides by pulling the edge guide knobs up and sliding to the position closest to the plate media width 3 Adjust the two front edge guides by loosening the screw and moving all the way to the front 4 Open the feed cassette by lifting the back of the lid and sliding forward at the same time Remove the spool assembly Adjust the left hub to match the edge guide position by squeezeing the clip and sliding on the shaft Remove the right hub from the shaft by lifting the clip and sliding it off the shaft Slide the media onto the shaft Slide the right hub onto the shaft by lifting the clip and pushing down on the spool until the spool is tight against the media see Figure I 2 Insert the loaded spool assembly back into the feed cassette with 12 of media remaining outside the cassette 5 Place the cassette onto the platesetter cassette mounting brackets 6 Feed media through the 1 set
16. 001 002 003 004 Quantity Component Used 1 4 4 12 Assembly Number 807083 001 ASSY CART EFFLUENT Number 807097 001 900832 003 900223 007 900222 003 Revision C Component Description Parts List Page 1 of 1 CART EFFLUENT CASTER TWIN WHEEL W O BRAKE WASHER LOCK HELICAL SPRING 5 16 REG NUT HEX UNC 5 16 18 PRINTWARE Confidential PART NUMBER AND REV LEVEL ON CENTER OF ou AE 4 PLACES GE 4 PLACES Printware ASSY CART EFFLUENT 807083 001 REVISION C PRINTWARE Confidential Sheet I of I Find Number 001 002 003 004 005 007 Quantity Component Used Assembly Number 806816 001 ASSY TANK EFFLUENT Number 900937 002 806718 001 806815 001 806803 001 806804 001 901118 001 Revision F Component Description Parts List Page 1 of 1 TANK 24 GALLON ASSY DRAIN VALVE ASSY PROBE EFFLUENT LEVEL PLATE TANK SUPPORT GASKET FITTING NUT PLASTIC PRINTWARE Confidential Printware ASSY TANK EFFLUENT 806816 001 REVISION E Sheet I of I PRINTWARE Confidential Find Number 001 005 006 008 010 011 012 013 014 015 017 018 019 020 021 Quantity Component Used N NN N N N NN KN n Assembly Number 808154 001 Number 808149 001 808203 001 808203 002 900047 000 807237 001 900229 010 600092 000 900287 019 900233 002 808192 001 900725 001
17. 040 041 042 043 044 045 046 047 048 049 050 Quantity Component Used a ON 00 h e O CON NN RR ms gt gt A A A 0 ON BRN Ne Assembly Number 808341 001 ASSY IMAGER PLATESTREAM 46 Number 808143 001 808344 001 803287 007 804140 003 808155 001 806005 001 806386 001 900270 009 900270 008 900270 007 900257 900222 003 900223 007 808202 001 523050 004 523190 004 523060 001 900261 004 900958 001 806843 001 803769 001 806709 001 900047 000 900445 006 900233 003 807222 001 806866 001 807223 001 804569 003 900223 006 900725 001 900287 007 900215 006 900341 003 806269 001 806494 001 806333 001 900222 007 900651 008 900173 001 900872 004 900872 008 Revision B Component Description ASSY CHASSIS PLATESTREAM 46 ASSY ROLLER TRANSPORT PLATESTREAM 46 ASSY POWER SUPPLY 110 220V ASSY CABLE INTERFACE SENSORS ASSY PROCESSOR ASSY OP PANEL FOAM LIGHTSEAL CASSETTE GAS CYLINDER 30 LBS GAS CYLINDER 75 LBS GAS CYLINDER 50 LBS STUD 10MM BALL 5 16 18 THREAD NUT HEX UNC 5 16 18 WASHER LOCK HELICAL SPRING 5 16 REG GUIDE PROCESSOR EXIT PCA STEPPER SHEAR CUTTER PCA STEPPER SHEAR CUTTER PCA INTERFACE 3240 RECEPTACLE 1 4 TURN NUT RECEPTACLE RETAINING ASSY PUMP BRKT PUMP MOUNTING ASSY PROBE WASHER EXTERNAL LOCK 8 SCREW B H TORX 8 32 UNC X 375 NUT LOCK 8 32 STOP TRAY ADJUSTABLE BLOCK TRAY ADJUSTABLE XP
18. 15 16 17 18 19 20 21 22 or 23 The 23 setting cuts all plates greater than 23 6 Miniplate Backup Enables calibration or elimination of the gap between jobs in Miniplate mode see Physical Calibration in the INSTALLATION GUIDE It also adjusts the gap between jobs in Cassette Mode 7 Guide B Sensor Turns the Guide B sensor On OFF The sensor should be ON to detect jams unless the sensor is damaged 8 Punch Only if punch option installed turns the punch on and off 2 10 CONTROL PANEL Run Hardware Menu Run Hardware ESC to exit Feed Motor OFF 7 Reset Proc Transport Motor OFF 8 Start Proc Exit Motor OFF 9 Prime Pump Cut Plate Shutter Close Punch Plate ON ESC OFF ENTER 1 Feed motor Turns off the feed stepper motor 2 Transport motor Turns on or off the capstan motor 3 Exit motor Turns on or off the Imager Exit motor 4 Cut Plate Cycles the cutter 5 Shutter Opens and closes the shutter 6 Punch Plate Cycles the Punch 7 Reset Proc Stops the processor and resets all of the counters 8 Start Proc Starts the processor to test for functionality of this section 9 Prime pump Turns on the processor pump for approximately five minutes 2 11 CONTROL PANEL Calibrate Menu Calibrate ESC to exit Calibrate Transport Calibrate Marker put Spool Manager arker Position 00 00 S
19. 2400 dpi optional Up to 175 line per inch 70 line per cm screen rulings 36 in min 91 cm min at 900 dpi 27 in min 69 cm min at 1200 dpi 18 in min 46 cm min at 1800 dpi 14 in min 34 cm min at 2400 dpi 18 1 46 cm 108 picas 18 1 x 22 max 9 x 12 min 46 x 56 cm max 22 9 x 30 5 cm min Automatically cuts to size Reduces leader to 0 7 1 8 cm Special imposition software allows up to 5 separate images per plate 650 nm red laser diode 780 nm infrared optional 25 micron nominal diameter 0 001 25 microns typical 4 consecutive plates 0 003 75 microns typical A 2 SPECIFICATIONS User Settings Right wrong reading and reverse Laser intensity 0 100 Resolution 900 1200 1800 2400 Variable Image offsets Recommended Media Silver halide polyester or paper plates 0 004 to 0 008 thick Imagesetting film with film handling option set Integrated Processor 2 bath design Adjustable automatic replenishment Adjustable developer bath temperature 75 F 95 F 24 C 35 C Adjustable dryer temperature 75 F 140 F 24 C 60 C PunchStream Integrated Punch Option Integrated punch option for Heidelberg GTO Ryobi 3300 series Hamada H234 and similar landscape and portrait presses Punching repeatability 0 001 25 microns Film handling Options Input cassette for daylight film loading Processor bypass take up cassette for up to 25 8M A
20. 900160 012 900039 001 900336 001 900445 006 900445 007 900047 000 900445 008 807191 002 806321 001 807093 006 807093 003 807093 004 807365 002 807365 001 806930 001 807193 001 807193 003 807193 004 806883 002 806883 003 ASSY SHROUD Revision G Component Description SHROUD STRIP NOISE SUPPRESSION BRACKET INPUT MEDIA ALIGNMENT BLOCK EDGE GUIDE ADJUSTABLE BLOCK EDGE GUIDE POSITIONING BRIDGE INPUT PLATE ADJUST PLATE POSITIONING BLOCK BACKUP BRACKET MOUNT LOWER BRACKET TOP SCREW SOCKET FLAT HEAD UNC 6 32 X 3 8 SCREW SHC 8 32 X 1 1 4 BLOCK LOCATING UPPER FRONT KNOB KNURLED SHC 8 SCREW SOCKET HEAD SHOULDER 8 32 X 6255 SPRING COMPRESSION 750X 360X 042 FOAM LIGHT BAFFLE SEAL EMI FOLD ASTRAGAL PLUNGER SPRING LOADED WASHER FLAT STEEL 8 NARROW SPACER 171 ID 25 OD 25 HT NUT SELF LOCKING HEX 8 32 SCREW B H TORX 8 32 UNC X 375 SCREW B H TORX 8 32 UNC X 500 WASHER EXTERNAL LOCK 8 SCREW B H TORX 8 32 UNC X 625 BLOCK LOCATING UPPER REAR PLATE BLOCK LOCATING LABEL PLATE GUIDE POSITION LABEL PLATE GUIDE POSITION EDGE GUIDE LABEL PLATE GUIDE POSITION EDGE GUIDE RECEPTACLE CASSETTE FRONT RECEPTACLE CASSETTE REAR PLATE BLOCK LOWER LOCATING SPACER LOCATING BLOCK UPPER SPACER LOCATING BLOCK 020 SPACER LOCATING BLOCK 015 STRIP NOISE SUPPRESSION STRIP NOISE SUPPRESSION Parts List Page 1 of 1 PRINTWARE Confidential 1 0 THIS SIDE SEE NOTE
21. E RING SAE 25 SHAFT CHANNEL DRIVE DRYER PRINTWARE Confidential Printware ASSY DRYER DRIVE 80671 4 001 REVISION PRINTWARE Confidential Sheet I of I Find Number 001 001 002 003 003 004 007 Ass Quantity Component Used 2 N uu N Number 900960 052 901119 001 806818 001 900960 057 901119 002 900302 008 901100 002 embly Number 806715 001 ASSY DRAIN Revision E Component Description Parts List Page 1 of 1 ELBOW 90 FITTING PVC PIPE ELBOW 90 DEGREE PIPE PVC TEE FITTING PVC PIPE TEE 3 4 CLAMP HOSE TUBING POLYVINYL CHLORIDE 1 1 4 X 1 PRINTWARE Confidential A CS ES AR 7 1 5 S 4 3 Y YN 6 1 HA gt Pus N 10 THIS SIDE SEE NOTE gt N 2 4 CK SAY TE 2 S nntware CHEN te d ASSY DRAIN 806715 001 REVISION E PRINTWARE Confidential Sheet I of I Find Number 001 002 003 005 006 007 008 009 010 011 012 013 015 016 019 020 021 022 023 024 025 026 028 030 032 033 034 035 036 037 038 039 040 041 Quantity Component Used 1 12 5 N NNN N NN ND ND BPN WN CO O m A ee tA Assembly Number 807328 001 ASSY STABILIZER TRANSPORT Number 807331 001 900960 004 900960 003 806752 001 900960 001 900229 017 806776 001 900960 020 900229 018 807332 001 806764 001 806852 001 80682
22. GRAY L2 J1 NU WHITE GND WHITE CAPSTAN STEPPER BLACK STEP BLACK 804628001 BROWN CUT STEPS BROWN RED GND RED ORANGE CUT RESET ORANGE YELLOW RESET YELLOW MARKER TRANS 1 BLACK 803323 002 1 1 BLUE WE GREEN GND GREEN 2 YELLOW 2 xD BLUE BLUE 3 RED 5 7 GREEN VIOLET PLGTOP VIOLET WHITE 1 BLACK de GRAY GND GRAY WHITE STEP SYNC WHITE EXIT STEPPER El E EE i J6 NU BLACK STEP SYNC BLACK 03666001 BNRR ala s Ls BROWN GND BROWN RED SPARES RED GR GRANGE SPARE3 ORANGE YELLOW GND YELLOW 1 BLACK 80332400 1 1 WHITE BLU 18 GREEN DIR GREEN ieee gt YELLOW T gt RED BLUE FD TR DIRT BLUE 3 RED 3 806792 001 gt VIOLET GND VIOLET 4 WHITE 2 4 BLACK PROCESSOR I mu am ane na FEFEUENT TANK LEVEL 523150 001 CABLE 806306 002 BLACK BLACK PS 806815 002 BROWN SPARED BROWN RED SPAREO RED SCHEMATIC PAGE 6 GRANGE ORANGE 806790 001 o sa amer YELLOW YELLOW CUTTER ASSY n End ANGI y E EX LI gt gt IOL 3 REPLENISHMENT TANK 0 WE us vor SARE VIOLET BACK m corn BLACK 5 FA E SPARE2 3 SHEAR CUTTER 2 21 1 SENSORS 806709 001 WHITE ND WHITE 3 BLACK 3 3 BLACK 1 wu ced BLACK GND BLACK 4 RED 3 RED MOTOR PUNCH 2 t ORANGE gt CABLE _ 804140 003 a 3 NU WHITE 3 WORKING TANK CABLE 807301 001 ORANGE NO MEDIA 45V y NO MEDIA 806127 001 SENSORS 806800 001 807226 001 NO MED
23. NUT LOCK K 4 40 SCREW PPH 10 32 X 3 8 WASHER EXTERNAL LOCK 10 SPACER THREADED HEX HINGE PROCESSOR DOOR HINGE PROCESSOR DOOR BRACKET DOOR HINGE BRACKET DOOR HINGE WASHER FLAT STEEL 8 NARROW Parts List Page 1 of 1 PRINTWARE Confidential dj d CANNES INN FITE LT oo s COCA Printware KIT CHASSIS PS46 8081 53 001 REVISION C Sheet I of 2 PRINTWARE Confidential 4 Printware KIT CHASSIS PS46 8081 53 001 REVISION C Sheet 2 of 2 PRINTWARE Confidential Find Number 002 003 004 005 006 007 009 010 011 012 014 015 017 018 019 020 022 023 023 024 029 031 032 033 038 042 043 047 048 049 050 051 052 053 054 055 056 060 064 065 067 068 Quantity Component Used Rh e N N N he N N e N e RRR NR bD DB Assembly Number 808344 XXX Number 808205 001 804288 001 808220 001 900297 001 803305 001 808218 001 900871 008 900928 002 822307 900229 002 807350 002 901023 001 900360 000 803418 001 803419 001 804627 001 803463 001 803466 001 808215 001 808208 001 808209 001 808214 001 808213 001 808212 001 804477 001 803744 001
24. Side View of Supply Cassette Top Front View of Supply Cassette Figure 3 3 Loading Film Media on Spool Cover G SLR Take up Cassette Capstan Roller Receptacles lt Feed Cassette o ku Y dr Guide C2 pins Guide D Guide F pins Feed Cassette L Processor exit Receptacles 1 5 Guide C1 pins Tank amp Cart Optional Cart Optiona Figure 3 4 Location of Optional Feed and Take up Film Cassettes 3 12 CHAPTER 4 OPERATING THE PLATESETTER Making a Plate Controlling Image Quality To maintain optimum print quality use only recommended media and processing chemistry and store all supplies properly Also perform the preventive maintenance procedures detailed in Chap ter 6 to keep the Platesetter clean and in proper operating condition Be sure all Platesetter covers are completely closed when making plates Once per week or more often if conditions require print a test plate and inspect the print quality If image quality problems are noticed perform the following adjustments Image quality problems may include slight changes in character stroke width image density or background density Refer to your RIP reference guide for instructions on printing a test plate Inspect the plate If image quality problems are found adjust the exposure as described in the next section Adjusting Exposure Laser Intensity See CALIBRATION in Appendix B 42 OPERATING THE PLATESETTER Re
25. Use grounded or nonmetallic tools whenever possible Do not attempt to open the inner covers other than described in this manual Be especially careful when working on or around the following areas of the Platesetter Marker Power Supply Assembly Processor SERVICE MANUAL The Platesetter is controlled by a Raster Image Processor RIP several different RIP options are available depending on the most common type of work to be done The system is driven by the host computer on which the operator composes the text and graphics to be imaged Once the print job has been composed on the host computer it is sent to the RIP where it is prepared for imaging The rasterized file is then sent to the Platesetter where the file is imaged onto a plate Figure S1 1 illustrates the basic system setup Figure 51 2 illustrates the dimensions and external features of the Platesetter Job stream character codes PEL plus command codes gt f External RIP File reconfigured commands interpreted Host Computer Figure 51 1 Interface Between the Host Computer RIP and PlateStream 46 SERVICE MANUAL Lc Right processor 12 30 rear clearance 24 60 cm left clearance Marker Lever _ k u N rd i 5 Load Knob ao p e gt u lt 7 47 119 P
26. WHITE GREEN WIRE 806420 004 FOR INTERNATIONAL USE BROWN BLUE GREEN YELLOW WIRE POSU OE CABLE 803321 001 RED ENG STP 45V ORANGE a ie ON ORANGE ENGSTP 424V FNO STEPPER BLACK PCA BLACK ENG STP_GND ORANGE 24V FAN MOUNTS TO BLACK GND FRONT OF POWER SUPPLY CABLE 803319 002 RED CONT 45V YELLOW CONT 12V CONTROLLER BLUE CONT 12V ORANGE CONT 24V BLACK CONT GND ORANGE VENT FAN 24 BLACK VENT FAN RTN DC POWER SUPPLY 901142 001 ALL FUSES CABLE 803312 003 PIN ASSIGNMENTS 250V 7A FROM BACK OF P S DRAWER 600322 001 RED 4 INTRF 5V ERE YELLOW INTRF 12V OP PANEL BLUE INTRF 12V ORANGE INTRF 24V BLACK INTRF GND RED 5V PLUG FOR POWER SUPPLY 522780 YELLOW OP 412V BLUE 12 GND 240 50 60 HZ 806420 TAB AC POWER COVER VENT FAN 900894 001 806504 001 ASSY CABLE FAN FILTER FAN MOUNTS TO FRAME NOT TO COVER CORCOM 30VK6 25 40 250V CABLE 806461 001 SWITCH CIRCUIT BREAKER CABLE 803334 001 POWER CORD CABLE 806461 001 BRKT CONNECTOR MOUNTING 807493 001 600307 001 OUTLET ACCESSORY TO POWER SUPPLY 600320 001 OUTLET 16 20A IEC 320 TO PROCESSOR WIRE COLOR DC POWER VOLTAGE PLUG MOUNTS TO BACK OF POWER SUPPLY DRAWN BY WMS 7 17 99 PRINTWARE INC ENG ENG APPVL DO NOT SCALE DRAWING ST PAUL MN MFG QA MATERIAL TOLERANCE UNLESS OTHERWISE SPEC
27. menu Once inside this menu move the cursor to 2 or simply press 2 to access the Calibrate menu In this menu move the cursor to 3 or simply press 3 to access the Calibrate Marker assembly menu The control panel will display are you sure Pressing ESC exits this menu without chang ing the marker assembly calibration Pressing ENTER will cause the control panel to display Power Cycle which means to turn the machine off and then back on 5 Close the top cover Interface PCA Location and Function The interface PCA is located underneath the imager towards the front See Figure S4 1 The interface PCA acts as an interface between the controller PCA and the Platesetter engine assemblies The interface PCA also receives the signals from the various sensors within the Platesetter The interface PCA also sends control signals to the engine stepper PCA to activate the stepper motors 32 SERVICE MANUAL Voltages Supplied to Interface PCA 12 VDC 12 VDC 5 VDC 24 VDC Connector Assignments J1 Not used J2 Not used J3 Track change solenoid J4 Not used J5 Shutter solenoid J6 Micro stepping controller J7 Not used 18 Not used J9 Not used J10 Not used 1 Engine stepper PCA 2 Controller PCA control panel communication cable J13 Not used J14 Processor communication cable J15 Sensors J16 Power Supply 33 SERVICE MANUAL Replacing the Interface PCA 1 Turn off the Plate
28. recap activator and stabilizer solution bottles tightly Store all chemicals in a well ventilated area Follow the manufacturer s instructions regarding safety storage temperature humidity and other environmental factors Rotate supplies to use the oldest items first Disposal of all chemicals must meet local environmental codes 54 CHAPTER 6 PREVENTIVE MAINTENANCE Introduction To avoid problems with the Platesetter maintain high print quality and to avoid unnecessary service calls follow the instructions in this chapter Keep all equipment clean and well maintained Perform regularly scheduled preventive maintenance Carefully follow instructions for the mix and use of chemistry Ink and press chemistry must be compatible Keep all solutions filled to the proper levels Handle plate media carefully Mount plates on the press properly Operator Maintenance Schedule recommendations based on 8 hours per day use 5 days a week 1 Imager section maintenance Roller cleaning only when necessary damp cloth light D ink no alcohol or solvents 2 Processor section maintenance a Roller cleaning weekly with warm water or mild soap no alcohol film processor cleaner or solvents b Guide cleaning weekly with warm water 3 Marker assembly mirrors Inspect every 6 months use canned air to remove dust particles only as needed 6 2 PREVENTIVE MAINTENANCE Maintenance Procedures Clea
29. the punch depth longitudinal position can be adjusted in the Opera tor Panel NOTE Before adjusting the punch ensure that the cutter has been adjusted correctly see previous sec tion Because the punch adjustment uses the cut edge as a reference the cutter must be adjusted first Lateral Alignment 1 To enable the punch from the Main Menu on the control panel Press 4 More Information Press 8 Punch Press ON to turn the punch on B o _ S 2 g x Q O Non operator side Adjustment Figure I 6 Lateral and Skew Punch Adjustments 1 25 INSTALLATION GUIDE 2 Run a test plate with the punch on NOTE Use the intended plate width for these adjustments Lateral alignment depends on the plate width 3 With a 9 32 Allen wrench loosen the two screws on either side of the punch assembly see Fig I 6 4 Centerthe punch pattern on the plate by adjusting the Lateral Adjustment Screw with a Phillips screwdriver Tightening the screw clockwise moves the punch pattern toward the operator side To move the punch pattern toward the non operator side loosen the screw counterclockwise and move the punch Each turn moves the punch approximately 0 030 5 Tighten the two screws on the non operator side of the punch assembly Leave the two screws on the operator side loose for adjusting skew Punch Skew 1 Loosen the two screws indicated in Fig I 6 on the operator side if
30. 312 SCREW BRKT CONNECTOR MOUNTING LABEL HEATER POT BLUE ARROW LABEL HEATER POT GRAY ARROW LABEL HEATER POT BLUE INST LABEL HEATER POT GRAY INST LABEL HEATER POT ACT TEMP LABEL HEATER POT DRY TEMP ASSY CABLE EXTENSION EXIT 1 PRINTWARE Confidential 139 INSTALL FROM A INSIDE MACHINE Aas 2 1981 DM c 68 3 8 3 3 98 m CUTOUT FROM REAR OF CHASSIS KCN E C N PRINTWARE Confidential a amp Printware ASS Y CHASSIS PS46 8081 43 001 REVISION B Sheet I of 7 PRINTWARE Confidential Printware ASS Y CHASSIS PS46 8081 43 001 REVISION Sheet 2 of 7 Printware ASS Y CHASSIS 546 8081 43 001 REVISION PRINTWARE Confidential Sheet 3 of 7 SEE DETAIL dcs A 188 ALL AROUND E SEE DETAIL in SEE DETAIL SEE DETAIL 9 185 Y 2 58 7 2 59 4 189 gt ff e R l E DETAIL A DETAIL DETAIL Antware ASSY CHASSIS PS46 8081 43 001 REVISION B PRINTWARE Confidential Sheet 4 0f 7 84 e NS V er N42
31. 6 1 2 3 5 6 WHEEL CUTTER 15 e 5 NU o SHEAR CUTTER 1 o DECURL EXIT STEPPER BOARD p LAY OUT CABLE 803118 001 PAPER FEED 1 GND BROWN 5 2 FD STEP RED 2 3 FD STEP ORANGE 3 4 GND YELLOW 4 WHEEL CUTTER 1 5 FD RESET GREEN 5 2 MARKER TRANS 6 FD BLUE 6 J1 NU 3 7 GND VIOLET 7 4 J4 5 i ENGINE STEPPER PCA Er 10 GND BLACK 10 523190 004 803666 00 1 11 TR RESET BROWN 11 12 TR RESET RED 12 ki 13 GND ORANGE 13 14 STEP YELLOW 14 PAPER FEED 1 1 E BLU 15 STEP GREEN 15 16 GND BLUE 16 J3 a 18 17 EX RESET VIOLET 17 4 96 18 GRAY 18 9 19 GND WHITE 19 CAPSTAN STEPPER CUT 8 20 CUT STEP BLACK 20 804628 001 BORD 9 21 CUT STEP BROWN 21 9 22 GND 22 23 CUT RESET ORANGE 23 MT J7 1 24 CUT RESET YELLOW 24 MARKER TRANS 1 3 1 INTERFACE PCA 25 GND GREEN 25 2 RD JJ 26 PLG OP BLUE 26 JA 3 3 27 PLG OP VIOLET 27 4 4 28 GND GRAY __ 28 29 STEP SYNC WHITE 29 EXIT STEPPER 30 STEP SYNC BLACK 30 803666 001 31 GND BROWN 31 32 SPARE 3 RED 32 33 SPARE 3 ORANGE 33 34 GND YELLOW 34 DECURL EXIT 1 1 ooo WHITE 35 FD TR DIR GREEN 35 36 FD TR DIR BLUE 36 J2 3 3 AS 37 GND VIOLET
32. 8 Punch OFF 2 Resolution 1800 DPI Jis cas 3 Image Power 25 2 Choose Pattern Composite Pattern 2 Calibrate M AIME aq 3 Choose Length 13 3 Status 4 Media Width 13 12 Spool Pos 13 4 Backup Feed Transport 5 Input Spool A On Line Idle A000 1800 DPI 5 Miniplate Cut Length 12 6 Destination Processor 6 Miniplate Backun ON 7 Display Units English PROG 4 a Sct N Run Hardware Calibrate Status 1 Feed Motor OFF 7 Reset Proc 1 Calibrate Transport 1 Sensor Status 2 Transport Motor OFF 8 Start Proc 2 Calibrate Marker 2 Takeup Cassette Remaining 25 3 Exit Motor OFF 9 Prime Pump 3 Input Spool Manager 3 Current Plate Count 125 4 Cut Plate 2 4 7 Total Plate Count 1234 5 Shutter Close Save Imager Setup to Material Used 1200 6 Punch Plate 6 Load Imager Setup from RIP Calibrate Transport 1 Calibrate Processor 2 Manual Length Adj 0 000 3 Cut Length Adj 1 950 4 Overlap Length Adj 0 725 5 Backup Length Adj 1 350 6 Punch Length Adj 1 500 7 Miniplate Backup Len Adj 0 031 Input Spool Manager 1 Spool A 0000 2 Spool 0000 3 Spool 0000 4 Spool D 0000 Sensor Status LOAD KNOB 0 WRKGN TANK LOW FEED LOOP 0 TANK LOW EXIT LOOP 0 EFFL TANK HIGH IMAGER EXITO PROC TEMP LOW 0 PROC EXIT LOAD OK 0 TAKEUP CASSETTE 0 GUIDE B 0 Figure 2 1 Control Panel Functional
33. 806327 001 808227 001 807068 001 806309 001 808199 001 901026 001 806623 001 806617 001 806618 001 901102 001 901070 003 803557 001 803741 002 803772 001 900569 001 900569 008 ASSY ROLLER TRANSPORT PLATESTREAM 46 Revision D Component Description WELDMENT ROLLER TRANSPORT ROLLER SEGMENTED 18 ROLLER FEED 18 BEARING BALL RETAINER BEARING BRACKET CAPSTAN DRIVE MOUNTING SCREW SHC LOW HEAD 1 4 28 X 1 5 NUT HEX JAM 5 8 18 WASHER PRELOAD SPRING M T E RING SAE 3 8 SHAFT ROLLER PINCH TRACTION 18 BUTTON LOCATING ADJ WASHER WAVE SPRING 22MM OD X 010 ASSY LOWER PINCH TENSION ASSY DRIVE EXIT ROLLER TENSION ASSY CAPSTAN DRIVE ASSY UPPER PINCH TENSION R H ASSY UPPER PINCH TENSION L H GUIDE UPPER EXIT GUIDE LOWER BUFFER GUIDE UPPER BUFFER GUIDE LOWER EXIT GUIDE UPPER CUTTER GUIDE LOWER CUTTER ROLLER ALUMINUM IMAGE ASSY PULLEY OVERRUNNING CLUTCH PLATE MARKER LOCATING LOWER BRACKET CUTTER MTG 46CM BRACKET CUTTER MOUNTING BRACKET CUTTER MOUNTING ASSY CUTTER 18 LATCH COMPRESSION ASSEMBLY ROD 5 16 SST HUB HANDLE SHAFT HANDLE KNOB OVAL TAPERD SCREW SET STAINLESS 10 32 X 188 SHAFT IDLER ARM BEARING PULLEY MOD PULLEY MOD 130 TOOTH W INSERT BELT TIMING 165 GROOVES 1 4 W BELT TIMING 184 GROOVES 1 4 W Parts List Page 1 of 4 PRINTWARE Confidential 069 071 072 079 083 084 085 088 090 092 093 094 106 107 108 110 118 119 120 121 122 123 124 125 126 128 129 130 131 13
34. 806352 002 806354 002 806870 001 803418 002 900257 806099 002 806099 001 807502 001 900236 003 ASSY ROLLER TRANSPORT PLATESTREAM 46 Revision D PLUNGER SPRING LOADED SCREW SOCKET HD SHLD 8 32 X 6255 SCREW TAPTITE PPH 8 32 X 50 SCREW SHC LOW HEAD 6 32 X 250 SCREW SHC 8 32 X 50 SCREW FLAT HD 6 32 X 5 SCREW SOCKET HD SHLD 10 32 X 500 SCREW TAPTITE PPH 8 32 X 3 8 BEARING NON METALLIC FLANGED SPACER SHAFT INNER WASHER NYLON WEAR 253 ID X 568 OD NUT HEX JAM 1 4 X 28 SCREW SHC 8 32 X 5 8 WASHER FLAT STEEL 8 NARROW SCREW SHC 8 32 X I 1 4 WASHER LOCK HELICAL SPRING 5 16 REG NUT HEX UNC 5 16 18 WASHER FENDER 434 X 160 X 125 SCREW B H TORX 8 32 UNC X 750 SPACER 375 ID X 093 THICK LABEL PLATE GUIDE POS EDGE GUIDE LABEL PLATE GUIDE POS EDGE GUIDE LABEL PLATE GUIDE POS PLATE ADJUST PLATE POSITIONING BLOCK BACKUP SPRING TENSION MOD ASSY LOWER PINCH TENSION STUD 10MM BALL 5 16 18 THREAD ASSY SOLENOID CAPSTAN GUIDE ASSY SOLENOID CAPSTAN GUIDE SPRING TRACTION CONTROL 18 SCREW SOCKET HD SHLD 8 32X 125 PRINTWARE Confidential ASSEMBLY A ASSEMBLY PRINTWARE Confidential ASSEMBLY P N ASSEMBLY S ASSEMBLY 2 Printware ASSEMBLY O 9 NE ASSEMBLY N ASSY R
35. 806794 001 WORKING TANK SENSORS 806800 001 ED PS 807204 001 EFFLUENT TANK LEVEL 806792001 n DRIER TEMP SENSOR C MOUNTING SCREW PS46 806815 001 Ny PS 806815 002 600330 001 806786 001 41 SENSORS BYE ERE ao oo A DRIVE MOTOR al 3E a gt II 806703 001 z I m 5 PIN 1 IS BROWN PIN 26 IS GREEN TP4 ACT DRYER Y mew Y TEMP ACT BLANKET HEATER ICAL 600335 001 TRANSFORMER WIRING DIAGRAM PS46 808155 001 PSMP 807546001 223150 001 PS 807179 001 806705 001 32 31 11 EMI FILTER 2A 250V SA 250V SA 250V HOOD INTERLOCK 2A 250V 600292 001 CEE ITIN DRYER HEATER 806712 001 TT PEYO WMS 320 99 ENG PRINTWARE INC CO APPVL Ili 2 wea ST PAUL MN 1 E QA did MATERIAL BLUE EN A 5 TOLERANCE UNLESS OTHERWISE SPECIFIEI Q ANGLEs BROWN lil POWER SUPPLY m 1 PLACE DECIM 29 FINISH 2 PLACE DECIMALS 02 YELLOW GREEN 220V 5 3 PLACE DECIMALS 010 Z Title REPLENISHMENT E WIRING DIAGRAM PlateStream 46 PUMPS 806843 001 Z COMM CODE Size INSP VERSION
36. 901089 007 900160 010 900233 003 900445 007 ASSY FILM OPTION Revision B Component Description ASSY CASSETTE TAKEUP BLOCK TAKE UP CASSETTE 46 BLOCK TAKE UP CASSETTE 46 WASHER EXTERNAL LOCK 8 PIN SWITCH ACTIVATOR E RING SAE 125 SHAFT SWITCH SLD ST MICRO N O L LEVER SCREW PAN PPH 4 40 X 75 NUT LOCK K 4 40 BRACKET SWITCH MOUNTING FEET ROUND 8 ROUND HEAD SCREW STNLSS TAP FORM 6 32X 75 WASHER FLAT STEEL 4 NARROW NUT LOCK 8 32 SCREW B H TORX 8 32 UNC X 500 Parts List Page 1 of 1 PRINTWARE Confidential SHOWN FOR REFERENCE ON LS PART NCE ONLY RE PART IS SHOWN FOR REFE e Printware ASSY FILM OPTION PS46 808154 001 REVISION 7 B Sheet I of I PRINTWARE Confidential Find Number 001 002 006 012 012 013 013 014 014 015 021 024 028 029 030 031 032 033 033 034 035 036 037 038 040 041 042 043 Quantity Component Used he Assembly Number 808243 XXX ASSY CASSETTE SUPPLY 280 Number 806625 002 806626 002 806342 001 806861 002 807464 002 806864 001 807466 001 806864 002 807466 002 807463 002 806416 001 900237 004 807437 001 900774 002 900236 015 807472 001 900233 807454 001 807454 002 807454 002 900047 000 900287 003 900047 002 900445 004 901244 001 900160 005 900157 006 807559 002 Revision Component Description ASSY SPOOL PLATE ADJUSTABLE ASSY SPOOL PLATE FIXED AXLE SPOOL HOUSING SUPPLY CASSETTE
37. A 2 184 187 IMAGER DOOR FRONT PROCESSOR DOOR 2 gt 2 P 2 142 SAN p d ye AE i ut ALL AROUND t ASSY CHASSIS PS46 808143 001 REVISION B Sheet 5 of 7 IMAGER DOOR REAR PRINTWARE Confidential PRINTWARE Confidential Printware ASSY CHASSIS PS46 8081 43 001 REVISION B Sheet 6 of 7 CONNECTION PLATE AS VIEWED 807493 001 BRKT CONNECTOR MOUNTING ai FROM INSIDE OF COVER FILTER FAN B POWER SUPPLY 800307 001 OUTLET ACCESSORY gt 35 806461 001 ASSY CABLE OUTLET PWR SUPPLY PROCESSOR BROWN GREEN BLUE 800272 500272 600272 000 03 000 GRAY GREEN GRAY m TERMINAL BL
38. Features Overview 1 5 Operator iii 1 7 Chapter 2 Control Panel The Control Peludo ee see ee t xs dadas 2 2 Control Panel Menus and Functions 2 4 Chapter 3 Preparing for Operation Preparing to Make 32 Filling the Processor 2 222 3 3 Loading Plate 3 5 Imaging Plates creare eere e eene torn due 3 7 Miniplate 3 9 Film Ordi TEE UE 3 10 Loading Optional Film 3 10 Chapter 4 Operating the Platesetter Controlling Image 4 2 Adjusting Exposure sss 4 2 Responding to Control Panel Error Messages 4 3 Chapter 5 Supplies INtFOGDUCTION 5 2 Recommended Consumabhbles 5 3 CONTENTS Tips on Supplies EE 5 4 Chapter 6 Preventive Maintenance open UTEM 6 2 Maintenance 2222 6 3 Chapter 7 Troubleshooting Print Quality 2 7 2 General 1 7 7 Clearing Media
39. Flowchart CONTROL PANEL The Power Up Sequence When the Platesetter power switch is turned on the Platesetter performs a sequence of tests of its internal components While the Platesetter is performing these tests the control panel display will show a series of status messages indicating the progress of the self tests If an error message is displayed correct the error according to the instructions in the Responding to Control Panel Error Messages section in Chapter 4 If the display stops at any initialization point for more than two minutes turn off the Platesetter and call for authorized service When the power sequence is successfully completed the display will show the Main Menu screen Main Menu Printware PlateStream 46 1 Setup 5 Load 2 Test Plate 6 Cut Fd 3 On Off Line 4 More Information On Line Transporting A0075 1800 DPI No Media Takeup Full LOW PROC TEMP HIGH EFF LOW REPL PROC ON ESC OFF ENTER 1 Setup Provides access to the Setup menu 2 Test Plate Provides access to the Test Plate menu 3 On Off Sets the Platesetter to either on line or off line The Platesetter must be on line in order to accept print jobs from the RIP The Platesetter cannot be set to On line if there is an error present Advancing the display to any of the sub menus automatically takes the Platesetter off line 24 CONTROL PANEL 4 More Information This selection provides access to seve
40. GU GU IDE B IDE Cl IDE C2 IDE D COVER G Press down on the four mounting pins and remove Inspect the CAPSTAN ROLLER for media wrapped around it Open the shutter if necessary The shutter is located on top of CAPSTAN roller Remove the front cover of the Platesetter Push the two mounting pins and swing the guide to the left Remove the front cover of the Platesetter Push the two mounting pins and swing the guide to the right Press down on the two mounting pins Slide the guide toward the front of the Platesetter Lift the rear of the guide and remove Remove COVER E Slide GUIDE F toward the rear of the Platesetter Lift the front end of the guide and remove Use the handle to remove 3 After locating the area of the media jam cut the media from the operator panel Run Hardware Menu 4 Remove all loose media in the Platesetter If the media is wrapped around the CAPSTAN ROLLER push the load knob in and back up the feed transport rollers from the operator panel More Information Menu 4 To stop the transport roller press the ESC or OFF key 5 Replace all guides in the original positions Gently close the MARKER and lock it by pushing down the MARKER LEVER Reload the plate material 7 10 IN CASE OF TROUBLE Imager Cover w Lever Marker Guide A pins Load Knob y Media path Guide B pins Guide 1 pins Capstan Roller Guide C2
41. Install AC power conditioner To diagnose intermittent DC problems track platesetter state at time of reboot e g was cutter cutting punch punching processor starting Check fuses in power supply Check voltages at controller PCA Specifications are 5 5 25V 12 0 6V and 24 1 2V Check the I O cable from the RIP Power cycle the Platesetter Reset the RIP Replace the controller PCA Verify that the lower cassette is properly loaded Check lower Load OK switch and cable Adjust lower Load OK switch 52 SERVICE MANUAL GENERAL IMAGER PROBLEMS cont All silver plates All silver plates usually indicates the shutter isn t Shutter problems opening properly 1 Check to make sure the correct media is used for printing and the emulsion side is up 2 Check that the shutter spring is in place and operating 3 Verify that the shutter plate isn t hitting the capstan roller To adjust loosen screws on the outside of the transport on the operator and non operator side Adjust the shutter plate to 1 32 to 1 16 0 8 to 1 6 mm from the capstan roller 4 Open and close the shutter from the Operator Panel hardware menu Run Hardware ESC to exit 1 Feed Motor OFF 7 Reset Proe 4 1 If the shutter solenoid isn t 2 Transport Motor OFF 8 Proc 3 Exit Motor OFF 97 Prime Pump operating check the solenoid 5 Shutter Close with an ohmmeter for a short or FP eh P ope
42. Plate Material Setting Replenishment Rates Changing Processor for 50 60 Hz Operation Physical Calibration Overview Cutter Skew Transport Skew Image Skew Scan Width and Linearity Adjustment Marker Position Adjustment Adjusting Image Length Adjusting Overlap Adjusting Cut Length Adjusting Backup Length Adjusting Miniplate Backup Length Punch Setup and Alignment Punch Adjustment Adjusting Punch Length De Installing the Platesetter Serial Numbers and Factory Settings 1 2 1 3 1 4 1 4 1 4 INSTALLATION GUIDE PLATESTREAM 46 PLATESETTER INSTALLATION GUIDE Pre Installation Checklist 1 Confirm Electrical Requirements Verify that the electrical power of the required voltage and current is available at the machine location Verify an Ethernet network drop is available at the RIP location The RIP requires a 10 Base T or thin coaxial cable The Platesetter requires a dedicated 200 240 VAC 20 amp 50 60Hz three wire single phase electrical line A 100 120 VAC 15 amp 50 60Hz line with a power strip is required for the Raster Image Processor RIP The RIP can be switched to 200 240 VAC operation The Platesetter is shipped without a power plug The Platesetter power cord length is approximately 9 3 meters The power plug used with the Platesetter must be rated for 20 amp 250 volt power and should have the proper safety certification for the country of use The electrical wiring color codes are North America Internation
43. PlateStream 46 PPD These are provided with the RIP If you don t have the Adobe driver the Linotype 630 driver can be used Note On Windows front ends specify the platesetter as a Local Printer not a Network Printer This allows selection of the correct spool folder at print time Print the Job a On Mac front ends ensure that the appropriate device name has been selected in Chooser and print normally from the application Do not specify screens or resolution in the application b On Windows front ends print to file from the application using the printer set up in step 3 the default printer name is PlateStream 46 the default printer name is PlateStream 46 when using the PlateStream 46 PPD Select the ZAPrip HQ and the appropriate hot folder GTO2up2400dpi in our example as the destination by browsing Network Neighbor hood Select the PlateStream 46 PPD if the application supports PPDs Do not specify screens or resolution in the application 05 4 Plate tream 46 Platesetter Installation Guide Printware LEADERS IN COMPUTER TO PLATE INSTALLATION GUIDE Contents Pre Installation Checklist Confirm Electrical Requirements Recommended Supplies Scheduling Installation Verify Final Location Precautions Unpacking and Inspection Assembling the Platesetter Joining the Imager and Processor Modules Assembling the Processor Installing the Raster Image Processor RIP Turning On the Platesetter Loading
44. REV amp FIRST USED ON B 700606 001 B SCHEMATIC PAGE 6 Teproduced copied disclosed to others or disposed SCALE NONE tion from Printware Inc Both the document and its contents are to be treated as confidential amp proprietary and may not be used any manner not consistent with the rights of Printware Inc Sheet 6 of 7 5 6 LIQUID CRYSTAL DISPLAY 522540 LCD ASSY 802533 KEYPAD 523180 001 UM OPERATOR PANEL ASSY 807148 001 SUPPLY DRAWER 6 XD3 XD2 ve XDO lt 85 o XSCL o NI lt VLCD X7 PS PG P lt PS gt x lt nj Y0 lt x loja lt N 1 lt Jf Jf Jf fro 20 BROWN RED ORANGE YELLOW GREEN BLUE VIOLET GRAY WHITE BLACK BROWN RED ORANGE YELLOW GREEN BLUE VIOLET GRAY WHITE BLACK CABLE 803311 003 10 11 12 13 14 15 16 17 18 19 20 SCHEMATIC PAGE 7 TO CONTROLLER PCA J9 AND TO INTERFACE 2 DRAWN proprietary and may not be used in any manner not consistent with the rights of Printware Inc BY WMS 7 17 99 ENG PRINTWAREINC ENG APPVL G ST PAUL MN E MATERIAL 5 TOLERANC
45. RRR gt Pan I I N N tA CO N Rep OQ OQ A 16 Assembly Number 808153 001 KIT CHASSIS PLATESTREAM 46 Number 807498 001 806619 001 806556 001 806557 001 808164 001 806608 001 806607 001 806607 002 808183 001 808184 001 901019 001 901019 002 900222 008 900223 009 900173 004 900223 006 900160 007 900287 003 900823 002 900594 004 900594 005 900047 000 806627 001 808186 001 806615 001 806634 001 900233 900224 005 806415 001 901103 002 900287 005 900160 008 900233 002 900288 003 900047 003 900904 002 806646 001 806646 002 806635 001 806635 002 900160 012 Revision C Component Description CHASSIS IMAGER CHASSIS PROCESSOR PANEL IMAGER FRONT 96 PANEL ACCESS PROC 96 INTERFACE CHASSIS PANEL IMAGER REAR 96 HINGE CONTINUOUS IMAGER HINGE CONTINUOUS PROCESSOR COVER PROCESSOR COVER IMAGER CASTER SWIVEL STEM W BRAKE CASTER SWIVEL STEM W O BRAKE UNC 1 2 13 WASHER LOCK HELICAL SPRING 1 2 REG BOLT HEX HD UNC THREAD 3 8 X 1 WASHER LOCK HELICAL SPRING 3 8 REG WASHER FLAT STEEL 3 8 SCREW PAN PPH 8 32 X 38 LATCH PULL FLUSH LATCH VISE ACTION LATCH VISE ACTION WASHER EXTERNAL LOCK 8 BRACKET CATCH MOUNTING PANEL ACCESS PROCESSOR PUMP BRACKET INTERLOCK BRACKET INTERLOCK MOUNTING NUT LOCK 6 32 SCREW TAPTITE PPH 8 32 X 50 PANEL ACCESS 54 CATCH SNAP IN SCREW PAN PPH 4 40 X 38 WASHER FLAT STEEL 4 REGULAR
46. Remove the roller by sliding the roller towards the front of the rack until it clears the frame 6 Install the new roller in reverse order Close the top cover 26 SERVICE MANUAL Replacing the Marker Unit CAUTION The Marker Housing contains potentially harmful invisible laser energy Do not attempt to open the inner covers other than described in this manual Construction and Function of the Marker Assembly Unit The marker assembly unit consists of a frame top cover lower cover laser lens assembly galva nometer reversing mirror spherical mirror folding mirror SOS sensor and SOT sensor The laser diode produces infrared light and is highly sensitive to ESD damage The galvanometer resonates at 540 Hz in a sealed vacuum chamber The marker assembly unit is mounted in an outer frame which is attached by two hinge assemblies to the Imager section chassis The controller PCA is mounted on the top of the marker assembly unit There is a lithium battery backup RAM on the controller printed circuit board U178 on 522980 XXX located on the top of the assembly This RAM lithium battery is not field replaceable Refer to the PlateStream 46 Platesetter Installation Guide for the installation of a new marker When a new marker assembly unit is installed in a Platesetter the new marker assembly unit calibration settings must be stored in the non volatile SRAM memory by the controller PCA This section describes the calibratio
47. Remove the sensor by removing the two screws holding the sensor in place 4 Install new sensor in reverse order Replace the front panel and close top cover NOTE The PROC EXIT sensor is located above the processor PCA See Figure 52 4 Load OK zl Feed Loop i er _ No Media Imager Exit 0 x L 4 Load Knob Exit Loop Figure 54 2 Front View of the Imager 40 SERVICE MANUAL 41 This page intentionally left blank SERVICE MANUAL CHAPTER 5 TROUBLESHOOTING Introduction This chapter contains procedures for isolating and correcting Platesetter problems in the field SZ CAUTION Operations with this symbol require advanced technical training 42 SERVICE MANUAL EXPOSURE PROBLEMS Weak image broken type or fine lines pinholes in solids Plugged images or exces sive background Setup 1 Image 2 Resolution 3 Image Power Media Width 13 12 6 7 Media Destination Display Units Verify that exposure is set correctly by checking see Operator Guide for details Laser power too high can cause text to break up on press output not the plates Reduce laser power Verify that exposure is set correctly by checking Laser power too low can cause plugged images and excessive background on press output not the plates Increase laser power ESC to exit ht Reading
48. TO CONTROLLER PCA J9 8 S GJ 8 z 9 9 3 S 9 2 9 amp J16 El ale 22 lal az Sl lal lel Sa zl II ES EL m CABLE 803311003 4 3 8 719 Zee gt lt gala PEPE FEE EEE SENERE 8 css mial olila Sis S S A gt s MO gt Ola gt s ESE2 CABLE ala a e e e e e ex e e e eo aaa a ka Fla 9 nn n 803118 001 8 AS 803312 003 Eee 15 3 CLAU gt c 1 BROWN V GND 1 SED 2 RED FD STEP 2 POWER 3 ORANGE FD STEP 3 uv SUPPLY YELTOW GND 1 DRAWER m 3 5 GREEN FD RESET 5 m 6 BLUE FD RESET 6 11 YELLOW 5 i 5 RA rm 9 WHITE TR STEP 9 14 BLACK 8 P Il BROWN RESET 11 INTERFACE 12 RED TR RESET 12 El 13 ORANGE GND 13 14 YELLOW EX STEP 14 15 GREEN EX STEP 15 523060 001 16 BLUE GND 16 INTERFACE 7 17 VIOLET EX RESET 17 BOARD LAY OUT 18 GRAY EX RESET 18 19 WHITE GND 19 i J1 NU 20 BLACK CUT STEP 20 e eg i 21 BROWN CUT STEP 21 22 RED GND 22 23 ORANGE CUT _ 23 24 YELLOW 24 I GREEN GND 55 ENGINE STEPPER i 26 BLUE PLG OP 26 J7 5 27 VIOLET PLG OP 27 I 28 GRAY GND 28 29 WHITE STEP SYNC
49. foam cap Remove the plastic wrapping from the unit Remove the front panel and the three strips of bubble pack Remove the metal shipping brace at the bottom of the Processor by removing the screws located above the front casters Remove and unwrap the bubble pack from the two replenishment tanks and the optional effluent tank located underneath the Processor Attach the ramp to the bottom of the crate using the two nails located in the front ofthe crate Close the top cover Remove the screws from the four wood blocks mounted to the bottom of the crate Remove blocks by slightly lifting the Processor Roll the Processor down the ramp and onto the floor carefully INSTALLATION GUIDE Assembling the Platesetter 1 Remove the screws holding the top and sides of the marker crate Carefully open the carton containing the marker assembly Remove the second cardboard cover from the marker assembly Cut the tie strap Identify the front and rear of the marker assembly the front has a warning label and serial number the rear has a grounding strap and welded hinge brackets Remove the foam block from the marker kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk CAUTION Do not set the laser marker assembly down on a flat surface This can damage the resonant galvanometer on the side of the assembly kkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk
50. halftone cell a completely black cell Dots of intermediate areas create the illusion of gray levels The number of pixels in the halftone cell defines how many intermediate areas of dot are possible and in most systems this defines the number of reproducible grays related to line screen m Cell spacing Figure ApB 1 Halftone cells Screen Frequency and Dot Shapes A screen is an invisible grid that is superimposed on the image each square in the grid is a halftone cell For a particular dot shape the important characteristics of a screen are its spatial resolution referred to as screen frequency and the screen angle as shown in Figure ApB 2 Screen angle Figure ApB 2 Screen Angle HALFTONING AND SCREENING Recommended Settings The best halftone strategy depends on the type of work media resolution and press characteristics but Printware makes the following recommendations for PlateStream computer to plate systems as a starting point Euclidian dots Figure ApB 2 shows circular and elliptical dots but dots can have other shapes These are described in detail in the RIP manual Euclidian dot shapes vary with the screen to minimize perimeter to area ratio which make them a good general purpose dot for black amp white or color printing 133 to 150 line Screens Default Angles Silver halide plate materials support a maximum of 175 line screens but accuracy and calibr
51. job Refer to your host computer operator manual and the RIP operator manual for further detail on connecting and operating these devices with the Platesetter Introduction Before making a plate the Platesetter must be Loaded with the correct type of plate media see chapter 3 in the section Loading Plate Media Connected to the RIP I O panel is located on the bottom rear of the machine Ready to accept a print job Main Menu displayed on the control panel On Line state no error conditions The integrated processor must be filled to proper levels see chapter 3 in the section Filling the Processor Tanks 3 2 PREPARING FOR OPERATION Filling the Processor Tanks Overview Fill the processor working tanks and replenishment tanks as needed Follow manufacturer s safety instructions The message LOW REPL will appear on the lower half of the control panel Main Menu when one or both of the replenishment tanks are low on chemistry The message LOW WORKING will appear on the lower half of the control panel Main Menu when one or both of the processor working tanks are low on chemistry The message HIGH EFF will appear on the lower half of the control panel Main Menu when the optional effluent tanks is full Once per week remove all chemistry and clean the processor section as described in Chapter 6 Preventive Main tenance Procedure 1 Open the top cover and bottom front doors Remove cover
52. lower cover 15 removed without prior authorization Only Printware authorized technicians may remove the Marker lower cover after receiving authorization from Printware Technical Support To obtain authorization to remove the lower cover contact Printware Technical Support by tele phone or FAX message Toll free U S A only 1 800 456 1400 FAX Number 612 454 3684 Be prepared to provide Technical Support with the following information Customer name Platesetter serial number Marker serial number Description of print quality problems you are having Description of Folding Mirror surface cleanliness Steps you have taken Request to remove Marker lower cover to inspect and possibly clean the other mirrors If appropriate Technical Support will authorize you by telephone or FAX message to remove the marker assembly unit lower cover to examine the other mirrors and to clean these mirrors if neces sary Technical Support may also offer suggestions to correct the print quality problem other than mirror cleaning 10 SERVICE MANUAL Inspecting the Galvanometer Window the Reversing Mirror Spherical Mirror and the Folding Mirror Get authorization to remove the marker lower cover See the previous procedure Open the top cover and raise the marker Remove the marker lower cover by unscrewing the 4 Allen head screws with flat washers located underneath the marker Refer to Figure 52 1 This will break the warranty vo
53. on focus test plate from the control panel Test Plate Menu 2 Inspect the plate under an eye loop at least 15 power Observe the cross hairs and the small dots Note that there are 2 patterns one is the negative of the other 3 Open the imager s top covers amp adjust the marker focus screw using a 7 32 allen wrench Turn the focus screw 3 full turns clockwise See Figure 52 1 Close covers Run another 4 pixel on focus test plate 4 Compare to previous plate If the focus pattern looks better you are turning the focus screw in the right direction Continue turning the focus screw 2 full turns at a time and re imaging another focus pattern and observe the results again 5 If the pattern looks worse turn the focus screw 6 full turns close the cover and run another focus pattern 6 Repeat whatever parts of steps 3 4 amp 5 that are necessary until test plates are in focus Note that there is approximately an 8 to 10 focus screw turn range where the marker is in focus The best focus will be obtained in the middle of that range 12 SERVICE MANUAL Note the sharp clean focused pattern above vertical and horizontal lines approximately the same width full sharp dots in both the positive and negative modes 4 pixel on focus patterns Note the fuzzy un focused pattern below vertical and horizontal lines are fuzzy and may not be the same width dots are fuzzy and small or even non existent
54. option the Platesetter will image film any width from 9 to 18 1 22 9 cm to 46 cm To turn the film option on change the destination to cassette in the Setup Menu see chapter 2 in the section Setup Menu This option is supplied with light tight feed and take up cassettes The film is fed from the feed cassette imaged and then fed into the take up cassette The take up cassette is easily removed and taken to another area for processing The feed cassette will hold up to 280 of film The take up cassette will hold up to 25 of film The cut Fd Key 6 on the control panel Main Menu will cut and feed any print jobs remaining in the Platesetter plus a leader into the take up cassette Loading Optional Film Media 1 Open the imager top cover Raise the marker by pulling the marker lever towards the front of the platesetter until the lever stops Lift up the marker gently See figure 3 4 2 Pull out the load knob on the left side of the platesetter From inside of the platesetter adjust the two rear edge guides by pulling the edge guide knobs up and sliding to the position closest to the film width 3 Adjust the two front edge guides by loosening the screws and moving the guides all the way to the front 4 Open the feed cassette by lifting the back of the lid and sliding forward at the same time Remove the spool assembly Adjust the left hub to match the edge guide position by squeezeing the clip and sliding on the shaft Remove
55. pins Guide D pins Processor Working Tanks Cover E Guide F pins L Processor exit Activator Stabilizer Figure 7 1 Clearing Media Path 741 IN CASE OF TROUBLE Calling For Service Overview To avoid most problems keep equipment clean and follow directions on all imaging and printing supplies Attempt to resolve the problem before calling for service Use the procedures and troubleshooting guidelines outlined in this manual Ifthe problem still cannot be resolved then follow the procedure outlined below Also call on an authorized service technician to perform preventive maintenance as required Steps for Calling for Service 1 Observe and write down the control panel error display if applicable 2 Turn off the Platesetter 3 Write down the Platesetter model number and serial number located on the rear cover 4 Be prepared to provide the service technician with a complete description of the problem 5 Only an authorized service technician should be allowed to service the Platesetter If you are unsure of whom to call to arrange for servicing then call Printware s Customer Service Department at 800 456 1400 7 12 APPENDIX SPECIFICATIONS SPECIFICATIONS General Resolution Throughput Image Width Plate Size Plate Cutter Waste Reduction Mode Miniplate Option Exposure Laser Spot Size Repeatability Image to Edge Accuracy 900 1200 1800 dpi
56. positions 2 When replacing rollers note that the new roller shaft may not be precisely the same length as the old roller shaft Install the spacer s on the rear of the shaft with the required thickness to eliminate any front to rear play Spacers are available in four thicknesses 0 016 0 4 mm nominal Part 900254 006 Spacer Inner Shaft 3 8 ID x 016 Th 0 048 1 2 mm nominal Part 900359 Spacer 375 ID x 047 Th 0 063 1 6 mm nominal Part 900254 003 Spacer Inner Shaft 0630 065 Th 0 092 2 3 mm nominal Part 4 900359 001 Spacer 375 ID x 093 Th 20 SERVICE MANUAL Replacing the Feed Rollers Lower and Upper Feed Stepper Motor and Feed Motor Belts See Figure S3 1 Pinch Roller Traction Centrol Belt Capstan Roller Belt Tensioner Pinch Roller Cutter Feed Rollers Imager Exit Rollers Belt Tensioner Feed Belts Imager Exit Belts a Feed Motor Imager Exit Motor Service Loop Exit Rollers Figure 53 1 Back View of the Imager 1 Open the top cover and raise the marker assembly Remove the back panel 2 Remove the bracket holding the pulley by unscrewing the three screws holding the bracket Remove the bracket holding the motor by unscrewing the four screws holding the bracket 3 Rotate the I shaped bracket located behind the pulley 90 and then slide the belts off of the gears 4 To repl
57. procedures Turn heat down on processor PCA by adjusting potentiometer R42 the tempera ture specification is 86 2 F or 30 1 Replace temperature probe SERVICE MANUAL PROCESSOR ELECTRICAL PROBLEMS cont Processor drive motor does not work Make sure the processor interlock switch is being activated If not adjust the switch bracket Remove both racks and turn on the proces sor If the motor comes on with the racks removed replace one rack at a time If adding a rack causes the motor to stop check the meshing of the gears and the roller end play of that rack Check the worm drive Remove the right side end panel and measure the voltage across motor If voltage reads 220V with motor on but the motor is not spinning replace motor If there is no voltage across the motor check fuse F5 on the PCA If the fuse is good replace the PCA Turn the white motor fan blade by hand If it doesn t turn easily disconnect the drive belt and try again If it still does not turn easily replace the motor assembly 70 SERVICE MANUAL MEDIA PROBLEMS Media has excessive curl 71 Check for excessive curl in media Lay 12 length of material on a flat surface and hold down one end If curl the is more than 2 replace media it does not meet the manufacturer s specifications Decrease dryer hood temperature potenti ometer R43 instructions on end panel
58. pulley 12 Check to verify that the solution is 86 F 30 C nominal activator temperature The activator temperature can be changed by adjusting a potentiometer R42 on the PC board Turning the screw clockwise increases the temperature if the potentiometer is blue Turning the screw coun terclockwise increases the temperature if the potentiometer is grey 13 Check to verify that the dryer temperature is 115 F 46 C nominal The dryer temperature can be changed by adjusting a potentiometer R43 on the PC board Turning the screw clockwise increases the temperature if the potentiometer is blue Turning the screw counterclockwise in creases the temperature if the potentiometer is grey 14 Printed circuit board removal Remove the wire tray located on the right side of the Platesetter Remove the right exit panel by unscrewing the four screws holding this panel Disconnect all the connectors There are nine quarter turn plastic standoff screws that hold the board on the printed circuit board bracket Rotate these screws 1 4 turn to free the board 15 Dryer heater element removal Remove the wire tray located on the right side of the Platesetter Remove the right exit panel by unscrewing the four screws holding this panel Remove the blower and mounting bracket There are 4 rubber isolators used to mount this assembly Remove the vertical cover panel that forms a part of the dryer plenum The heater is mounted on the inside of this cover
59. rollers from the top of the Platesetter As the feed rollers are rotating clean them using a soft cloth and D Ink See Figure 6 1 Press the OFF key to turn off the feed motor then press ESC 4 Turn on the capstan motor by pressing the 2 key and then the ON key Access the rollers from the top of the Platesetter and open the shutter As the pinch and capstan roller are rotating clean them using a soft cloth and D Ink Press the OFF key to turn off the transport motor then press ESC 5 Turn on the imager exit motor by pressing the 3 key and then the ON key Access the upper roller from top of the Platesetter Remove the front panel to access lower roller from the side of the Platesetter As the imager exit rollers are rotating clean them using a soft cloth and D Ink Press the OFF key to turn off the exit motor then press the ESC key 6 Press the ESC key again to return to the Main Menu then press the 3 key to return the Platesetter to the on line mode co Replace the front panel Gently lower the marker and lock by pushing marker lever towards the rear of the Platesetter until lever is horizontal Close the top cover 6 4 PREVENTIVE MAINTENANCE Cleaning the Processor Module For optimum performance of the processor module it is important to keep all chemistry filled to the proper levels and clean the machine weekly to prevent a buildup of chemistry
60. the loaded spool assembly back into the feed cassette with 12 of media remaining outside the cassette 5 Place the cassette onto the platesetter cassette mounting brackets 6 Feed media through the 1 set of rollers and 2 edge guides 7 Rotate the cassette up and lock into place on the platesetter Be sure the media is not pinched between the cassette and the platesetter 8 From inside the platesetter push the media up through the next edge guides and into the nip of the pinch roller 9 Set the front edge guides up against the media and tighten the screw 10 Gently lower the marker and lock down by pushing the marker lever towards the rear of the platesetter until the lever is horizontal Close the top cover gt 11 Set the plate width from the control panel setup menu Optional Adjust the feet remaining feature on the control panel input spool manager menu 35 PREPARING FOR OPERATION 12 Push the load knob in This will automatically load the plate material The control panel must be in the main menu or the test plate menu for this automatic feature to work NOTE Pressing the load key 5 on the control panel main menu will also start the load media process 13 Image one test plate from the control panel Test Plate menu NOTES Destination must be set to Processor see the PlateStream 46 Platesetter Operator Manual for control panel procedures Cut off any punched area of plate be
61. the right hub from the shaft by lifting the clip and sliding it off the shaft Slide the film onto the shaft Slide the right hub onto the shaft by lifting the clip and pushing down on the spool until the spool is tight against the film see Figure 3 3 Insert the loaded spool assembly back into the feed cassette with 12 of film remaining outside the cassette 5 Place the feed cassette onto the platesetter cassette mounting brackets see Figure 3 4 6 Feed media through the 1 set of rollers and 2 edge guides 3 10 PREPARING FOR OPERATION 7 Rotate the feed cassette up and lock into place on the platesetter Be sure the film is not pinched between the cassette and the platesetter 8 From inside the platesetter push the film up through the next edge guides and into the nip of the pinch roller 9 Set the front edge guides up against the film and tighten the screws 10 Open the processor cover and remove guide D by pressing the guide towards the front of the platesetter Life the guide from the back of the platesetter and remove 11 Place the slot on the take up cassette over the imager exit guide Place the top two metal pins attached to the take up cassette in the slot in the two black take up receptacles and push down 12 Gently lower the marker and lock down by pushing the marker lever towards the rear of the platesetter until the lever is horizontal Close the top covers 13 Set destination in set up menu to cassette
62. the user selected resolution 900 1200 1800 or 2400 scan lines per inch Once the correct number of scan lines have been imaged the marker unit keeps the laser turned on to expose the trailing edge of the plate Once the entire page is imaged the media advances to the cutter The cutter cuts the media to a specified plate length After the media is cut it is fed between the upper and lower imager exit rollers and into the integrated processor 2 Activating Developing a base chemical process which etches the image on the media This is done by the activator on silver halide plate material 3 Stabilizing Fixing a slightly acidic chemical process which stops the developing This is done by the stabilizer on silver halide plate material 4 Drying air drying of the processed media Unless another file is sent immediately the Platesetter returns to idle mode The feed capstan and imager exit motors are shut off The processor transport motor and dryer are also shut off Imager Cover y Lever Dryer Cover G Processor Guide A Capstan Roller Working Tanks pins y Load Knob Cover E ER Guide C2 pins i ins 4 i B ude D pins Guide F pins Media path x Guide B pins dg sie 7 PE Processor exit En ue di Guide C1 pins d z Activator Stabilizer Effluent Drain gt A Optional Effluent Tank 2 VA O O T
63. they have not been loosened for lateral adjustment 2 Measure the location of the punch pattern relative to the grid pattern on the test plate Refer to Fig I 7 f A gt B non operator side deeper loosen the 4 locking screws and turn the Skew Adjustment Screw clockwise Each turn moves the punch approximately 0 030 0 08 cm If A B operator side deeper turn the Skew Adjustment Screw counterclockwise 3 After adjustment run another plate to check for punch skew 4 Continue adjusting punch skew until the punch pattern is sufficiently parallel to the cut edge 5 Tighten the two screws indicated in Fig I 16 on the operator side Operator side notch arid Pattern Non operator side notch lt Lateral Punch Alignment gt Figure 7 Punch Alignment and Skew 1 26 INSTALLATION GUIDE Adjusting Punch Length 1 To enable the punch from the Main Menu on the control panel Press 4 More Information Press 8 Punch Press ON to turn the punch on 2 Run a test plate with the punch on 3 Return to the Calibrate Transport menu 4 Measure the depth or position of the punch notch see Figure I 16 5 For the Bacher punch pattern the notch depth should be 0 433 11 mm For the pin bar pattern the center of the holes should be 0 3125 7 94 mm from the edge To increase the depth increase the value for Punch Length Adj and increase Backup Length Adj by the same am
64. towards the rear of the Platesetter until it clears the frame Access the lower roller from the front side of the PlateStream Press down on the two Guide B pins and swing Guide B to the left Remove the lower roller by sliding towards the front of the Platesetter until it clears the frame 8 Install the new rollers in reverse order 25 SERVICE MANUAL Cutter Assembly Construction of the Cutter Assembly See Figure S3 1 The cutter assembly consists of a frame DC motor and position sensor 1 Open the top cover and raise the marker 2 Disconnect the cutter cable assembly 3 Remove the 4 Allen head screws which hold the cutter to the plate 4 Access the cutter assembly from the top of the Platesetter and remove 5 Install the new cutter in reverse order Replace the rear panel Lower the marker and close the top cover Replacing the Processor Rollers See Figure S2 2 S2 3 There are thirteen rollers six in the activator rack and seven in the stabilizer rack 1 Open the top cover 2 Remove Cover E Remove Guide F by pressing guide towards the rear of the Platesetter lift guide from the front of the Platesetter and remove Remove Guide D by pressing the guide towards the front of the Platesetter lift the guide from the back of the Platesetter and remove 3 Remove the rack from the Platesetter 4 Remove the gear from roller by loosening one set screw Remove the spring if any and the bearing if any 5
65. 0 Tip Some densitometers require special procedures to measure densities of less than 10 consult your densitometer manual 3 Click New to create a new calibration set for the first time The RIP manual describes how to useall the items in the Edit Calibration dialog box but the essential items are as follows Set the PlateStream for negative right reading b Set Measurements as negative dot c Check Negative media for film plate material is positive media d Check Force solid colors indicating that the PlateStream is a halftone device e Enter the dot percentages from the densitometer readings f In the Warning criteria panel enter the settings used to create the target resolution dot shape and the range of screen frequencies for which this calibration set can be used 4 Save the set by clicking the OK button in the Calibration Manager dialog If you click the Cancel button in the Calibration Manager dialog you lose the changes 5 Select a calibration set from the Calibration drop down list in the Page Setup dialog box in order to associate it with a page set up 6 Print a calibrated target to check calibration A single pass new calibration should be accurate to within about 2 For greater accuracy you can do a second calibration iteration by editing the values in the calibration set with the densitometer readings from the calibrated target Edit from calibrated target 7 Repeat this proces
66. 1 001 806837 001 806760 001 806278 001 806836 001 900967 001 901072 004 901071 013 900967 003 901072 005 901089 001 806822 001 806694 002 806510 001 901070 001 806819 001 900319 004 807231 007 806695 001 900773 001 900968 005 900215 007 807225 005 Revision Component Description PLATE STABILIZER FRONT BEARING ROLLER GEAR ASSY GEAR SHAFT IDLER GEAR SPUR E RING SAE 25 SHAFT STUD GEAR GEAR SPUR E RING SAE 312 SHAFT PLATE STABILIZER REAR BRACKET DRIVE RACK ASSY CLUTCH WORM GEAR SHAFT DRIVE RACK ASSY STABILIZER ENTRANCE GUIDE HANDLE RACK ROLLER SQUEEGEE POLISHED ASSY PROCESSOR GUIDE SCREW STAINLESS 8 32 X 375 PHILLIPS PAN HEAD WASHER SPRING LOCK STAINLESS 8 WASHER FLAT STAINLESS 10 SCREW STAINLESS 10 24 X 375 PILLIPS PAN HEAD WASHER SPRING LOCK STAINLESS SCREW STAINLESS TAP FORM 10 24 X 1 ROD SUPPORT SPRING EXTENSION ROLLER PROCESSOR ASSIST SCREW SET STAINLESS 8 32 X 250 GEAR MOD BEARING NON METALLIC FLANGED LABEL GUIDE COVER GUIDE F COLLAR GEAR COLLAR SHAFT NUT STAINLESS 10 24 KEPS LOCKNUT WASHER NYLON 1 4 X 5OD X 032 THK LABEL STAB Parts List Page 1 of 1 PRINTWARE Confidential 5 BOTH ENDS D S x a 807328 001 REVISION Sheet I of 3 PRINTWARE Confidential Printware ASSY STABILIZER TRANSPORT S WRAP ITEM 31 AROUND BOTH BEARINGS 2 PL 807328 001 REVISION C Sheet 2 of 3 PRI
67. 2 134 135 136 137 142 151 152 154 158 160 161 163 164 165 Oh NO Fe e e CN 9 BRN N N Ne KF 2 BRK N OO oo oo Assembly Number 808344 XXX 900569 037 80845 1 001 808450 001 806228 001 806239 001 807216 001 807215 001 807064 001 807354 001 807356 001 807363 001 807359 001 807091 001 808197 001 808 197 002 80709 1 004 806330 001 806347 001 806348 001 900229 001 806199 001 900235 013 803666 001 806393 001 806389 001 900160 006 900225 001 900236 012 900047 003 900288 000 900406 006 806267 001 806585 001 900254 002 900039 001 804574 001 900582 007 80633 1 001 808 152 001 806360 001 80638 1 001 807066 001 807067 001 900223 004 ASSY ROLLER TRANSPORT PLATESTREAM 46 Revision D BELT TIMING 434 GROOVES GUIDE INPUT LOWER GUIDE INPUT TOP BRACKET LOWER SOLID MOUNTING BRACKET UPPER GUIDE MOUNTING BLOCK EDGE GUIDE POSITIONING BLOCK EDGE GUIDE ADJUSTABLE BRIDGE MEDIA INPUT PULLEY MOD 65 GR ASSY PULLEY OVERRUNNING CLUTCH ASSY BELT TENSIONER SHAFT BELT TENSIONER ASSY SWITCH ASSY CABLE EXTENSION LOAD OK ASSY CABLE EXTENSION EX LOOP ASSY SWITCH ARM IDLER BRACKET IDLER SHAFT IDLER E RING SAE 1 4 SHAFT PULLEY MOD SCREW SHC 6 32 X 25 ASSY MOTOR MOUNT BRACKET BEARING SUPPORT BRACKET GAS CYLINDER WASHER FLAT STEEL 10 WASHER FLAT STEEL 25 DIA SCREW SOCKET HD SHLD 10 32 X 2505 WASHER EXTERNAL LOCK 10 SCREW PPH 10 32 UNF X 1 2 BEA
68. 29 i J6 NU 30 BLACK STEP SYNC 30 e 31 BROWN GND 31 32 RED 32 33 ORANGE SPARE 3 33 34 YELLOW GND 34 35 GREEN FD TR DIR 35 1 36 BLUE FD TR DIR 36 5 37 VIOLET GND 37 38 GRAY SPARE 38 Chie i J4 NU 39 WHITE SPAREI 39 806306 002 40 BLACK GND 40 4 BROWN SPARE 0 41 42 RED SPARE 0 42 43 ORANGE GND 43 AMEN a 44 YELLOW EX DIR 44 24V mac 2 FAN DRV WHITE 2 T EM cu 47 VIOLET SPARE 2 47 COOLING FAN 48 GRAY SPARE 2 48 49 WHITE GND 49 50 BLACK GND 50 CABLE 804140 003 WHITE 1 J NU wur 3 1 BROWN MEDIA 5V NO MEDIA 807301 001 ORANGE 3 SENSOR NO 807091 001 CABLE n YELLOW LOAD OK 5V TOAD OK 806099 601 807226 001 SENSOR NO SAUTER ail 807091 001 24V ORANGE 1 VIOLET LOAD KNOB 45V TOAD KNOB SHUTTER DRV WHITE 2 SENSOR WHITE 24y ORANGE WHITE LOAD KNOB GND te varme suurmx avs wame SHUTTER DRV WHITE 4 10 BLACK EXIT CASSETTE 5V KIT CASSETTE USEDONLY BROWN EXIT CASSETTE SIG SENSOR NO 12 EXIT CASSETTE GND 8079912291 OPTION CABLE 806376 001 17 ORANGE TENU 14 YELLOW NU I WORKING TANKS LOW 1 15 GREEN NU 16 BLUE NU 2 REPLN TANKS LOW ORANGE 3 17 VIOLET EX LOOP 45V EXITIOOP 15 GND YELLOW 4 SENSOR NO 3 EFF TANK HIGH GREEN 5 19 WHITE EX LOOP GND SO 09 001 16 GND BLUE 6 20 BLACK FEED LOOP 5V 4 _ PROC TEMP VIOLET 7 SENSOR NO 17 GND GRAY 8 22 RED FEED L
69. 3 SPECIFICATIONS ZAPrip Raster Image Processor Options Adobe PostScript ZAPrip ZAPrip HQ Harlequin interpreter ZAPrip 200 HyWay interpreter RIP Network Protocol Options Novell NetWare Mac AppleShare Physical Dimensions Dimensions 47 h x 52 w x 35 d 119 cm x 132 em x 89 cm Weight 75063 71013 Environment Electrical Requirements 220 240V 50 60Hz 4400 VA Temperature 65 F 80 F 18 C 27 C operating 40 F 150 F 40 C 65 C non operating Relative Humidity 45 to 70 operating non condensing A 4 APPENDIX CALIBRATION CALIBRATION Introduction This appendix provides tips for calibrating the PlateStream Following these procedures will provide the best results especially when printing screens Calibration has two major steps I Setting maximum density D ___ in solid black areas by adjusting the laser power II Linearization of the dot percentage transfer curve by calibrating the RIP PlateStream users doing critical screens have found it helpful to calibrate the platesetter weekly or more often if required and replace the processing chemistry every two weeks or more often if required I Setting Maximum Density Before calibrating dot density maximum density D is set by adjusting laser power from the PlateStream operator panel There are several ways to do this A Using an exposure file 1 From the RIP run file 805346 1 ps using the lowest resolution t
70. 37 4 4 38 SPAREI GRAY 38 39 SPARE WHITE 39 40 GND BLACK 40 41 SPAREO BROWN 41 CUTTER ASSY 42 SPAREO RED 42 43 GND ORANGE 43 44 EX DIR YELLOW_44 SHEAR CUTTER 1 BLACK 45 EX DIR GREEN 45 7 wie 46 GND BLUE 46 J8 47 5 2 VIOLET 47 RED cure moror 48 SPARE GRAY __ 48 49 GND WHITE 49 50 GND BLACK 50 806127 001 1 2 3 4 5 6 NU 5 J6 NU 7 8 9 CABLE 803321 001 10 11 12 2 24V ORANGE 4 SUPPLY DRAWN WMS 6 30 99 DRAWER ENG PRINTWARE INC ENG 7 GND_ BLACK 5 7 o a ST PAUL MN QA MATERIAL TOLERANCE UNLESS OTHERWISE SPECIFIEI ANGLES 5 DEG 1 PLACE DECIMALS Ex FINISH 2 PLACE DECIMAL 02 3 PLACE DECIMALS 010 Title WIRING DIAGRAM PlateStream 46 COMM CODE DO NOT SCALE DRAWING FIRST USED ON Size B INSP VERSION REV 700606 001 7 SCHEMATIC PAGE 5 This document and the information it contains is the property of Printware Inc and may not b SCALE NONE reproduced copied disclosed to others or disposed of directly or indrectly without authoriza tion from Printware Inc Both the document and its contents are to be treated as confidential amp Sheet 5 of 7 proprietary and may not be used in any manner not consistent with the rights of Printware Inc 6 DB25 PINCONNECTOR MOUNTS ON SIDE OF IMAGER EXIT SWITCH 600333 001 RIBBON CABLE TO INTERFACE BOARD PS46
71. 5V PULL UP VIOLET 37 RAY 3 sav E ST PAUL MN WHITE 5V PULL UP WHITE 19 BROWN G BROWN 3 asv Y 3 MATERIAL T SUIT 3 i SIG SENSOR NO 7 OND BLACK ANGLES 5DEG BROWN 35 PULLUP BROWN 21 ORANGE EXIT I GND NS T gt 807091 001 I PLACE DECIMALS FINIS RED SPARE RED 2 LOWS NU FINISH ORANGE NU ORANGE 9 d 2 PLACE DECIMALS YELLOW NU mon E 3 3 PLACE DECIMALS 010 GREEN NU GREEN 25 wama Gi Title E 2 VIOLET GUIDE B 45V G T E SM CET RR WIRING DIAGRAM PlateStream 46 WHITE GUIDE B GND paa q 806794 001 DB25 CONNECTOR NU J13 BLACK NU 30709100 2 COMM CODE Size 700606 001 INSP VERSION REV CABLE MOUNTS TO SIDE OF IMAGER FRSTUSEDON B B This document and the information it contains is the property of Printware Inc and may not be SCALE NONE El reproduced copied disclosed to others or disposed of directly or indrectly without authoriza d tion from Printware Inc Both the document and its contents are to be treated as confidential amp Sh 1 f 7 proprietary and may not be used in any manner not consistent with the rights of Printware Inc Sheet 2 s 7 1 2 3 4 5 6 TAB BLOCK POWER SUPPLY INTEGRATED ASSY PART NO DESCRIPTION 807046 TAB 807046 001 NORTH AMERICAN 807046 501 INTERNATIONAL 806420 003 FOR NORTH AMERICAN USE BLACK
72. 7 002 806830 001 806827 003 806827 004 Revision E Component Description PANEL ELECTRICAL LOWER CLIP CORD ADHESIVE ASSY CABLE HEATER CONTROL ASSY CABLE MOTOR CONTROL ASSY CABLE DRYER HEATER BUSHING GROMMET LABEL POWER SUPPLY ASSY STRIP 1 ASSY STRIP TS2 ASSY CABLE GROUND ASSY CABLE POWER CONTROL SCREW STAINLESS 4 40 X 375 NUT STAINLESS 4 40 X HEX LOCKNUT SCREW STAINLESS 8 32 X 5 PHILLIPS PAN HEAD WASHER EXT STAINLESS 8 MOUNT TIE TIE NYLON ASSY CABLE JUMPER 3 50 ASSY CABLE JUMPER 4 50 ASSY CABLE PROCESSOR MOTOR ASSY CABLE JUMPER 3 50 ASSY CABLE JUMPER 3 75 Parts List Page 1 of 1 PRINTWARE Confidential A FROM REFERENCE TSI 1 1 TSI 1 TSI 4 806827 003 ITEM 27 TS1 2 GND 1 806825 001 ITEM 11 TS1 2 TS1 6 806827 001 ITEM 21 TS1 3 P8 3 TS1 3 8 4 751 4 52 3 806827 004 ITEM 28 TS1 4 DRIVE MOTOR 806830 001 ITEM 23 TS1 4 BLOWER FAN MOTOR BLACK TS1 5 5 1 sar TS1 5 BLOWER FAN MOTOR BLACK TS1 6 TS2 1 806827 002 ITEM 22 TS1 6 DRIVE MOTOR 806830 001 ITEM 23 TS1 6 BLOWER FAN MOTOR GREEN YELLOW TS1 7 DRIVE MOTOR 806830 001 ITEM 23 TS2 1 P8 2 TS2 1 TS2 6 806827 001 ITEM 21 752 2 5 2 5 TS2 3 TS2 8 806827 003 ITEM 27 152 3 P13 1 gas TS2 4 P13 2 152 4 P4 2 752 5 Pl33 TS2 5 P4 3 ce TS2 6 P13 4 182 7 P4 1 TS2 7
73. 800 DPI 5 Spool Pos 13 Upper Spool Input Spool A Processor English ON ESC OFF ENTER Setting laser power setup menu item 3 43 EXPOSURE PROBLEMS cont Uneven density from center to edges Hazing on fine print or fine lines Going around in circles adjusting laser power 2 ES SERVICE MANUAL Calibrate densities Customized firmware can correct slightly uneven density profiles Send several half black half white sample plates from the Operator Panel test plate menu at the resolution of interest to Printware Refocus marker Verify that exposure is set correctly by checking Increase laser power Turn laser fogging circuit up turn potentiometer clockwise 60 or 10 minutes Note original potentiometer position If resetting does not alleviate problem return to original position Note that increasing laser power on plates increases density in black non image areas and decreases line thicknesses Use the following typical Operator Panel laser power settings as a sanity check Typical laser power setting RED INFRARED 900 DPI 65 85 50 60 1200 DPI 55 75 40 50 1800 DPI 45 65 30 40 2400 DPI 35 55 20 30 44 SERVICE MANUAL IMAGE QUALITY PROBLEMS ARTIFACTS Thin line artifacts 1 Ensure laser exposure is set correctly Scan lines 2 Intermittent horizontal artifacts could be caused by improperly set service loops 2 1 Feed l
74. 87 020 900160 005 900336 001 900047 003 900652 014 900288 000 900445 900223 005 900340 003 900160 006 Revision Component Description PLATE DRIVE MOUNTING PLATE PULLEY MOUNTING BASE PLATE PULLEY MOUNTING LEFT SIDE PLATE PULLEY MOUNTING RIGHT SIDE PLATE MOTOR BRACKET MOUNTING BRACKET MOTOR MOUNTING CAPSTAN CAPSTAN DRIVE BRG ADJUST PULLEY COATED CAPSTAN LOWER BELT FLAT BELT FLAT 11 50 X 400 X 018 ASSY MOTOR STEPPING GROMMETS VIBRATION ISOLATOR BEARING BALL FLANGED E RING SAE 1 4 SHAFT SCREW SKT HD CAP UNIF 10 32 X 1 2 SCREW SHC 6 32 X 25 WASHER EXTERNAL LOCK 6 SCREW PAN PPH 8 32 X 1 00 WASHER FLAT STEEL 8 NUT SELF LOCKING HEX 8 32 WASHER EXTERNAL LOCK 10 SPACER ROUND 48 X 1 4 SCREW PPH 10 32 UNF X 1 2 SCREW B H TORX 10 32 X 625 WASHER LOCK HELICAL SPRING 10 REG SCREW SKT HD CAP UNIT 10 32 X 3 4 WASHER FLAT STEEL 10 Parts List Page 1 of 1 PRINTWARE Confidential lt 1 0 THIS SIDE j SEE NOTE 1 Printware ASS Y CAPSTAN DRIVE 804627 001 REVISION K PRINTWARE Confidential Sheet of I Find Number 001 002 003 004 005 006 007 008 014 016 Quantity Component Used PB oR ON Assembly Number 803666 001 ASSY MOTOR MOUNT Number 806098 002 803665 001 806199 001 900767 001 900652 014 900287 016 900160 004 900336 000 900160 011 900235 013 Revision N Component Description Parts List Page 1 of 1 ASSY MOTOR TAKEUP DRI
75. ACT TANK HEATER pee TS2 B ACT TANK HEATER TEE 80798 00 PRINTWARE Confidential I E 806797 001 m TD BLOWER FAN MOTOR Printware ASSY ELECTRICAL PANEL 806708 001 REVISION E Sheet I of I Find Number 001 002 004 008 009 010 012 013 014 016 017 018 Quantity Component Used 1 1 15 A N Ne 60 Assembly Number 808228 001 ASSY TRANSPORT DRYER ROLLER Number 808229 001 80675 1 001 901077 001 900230 002 806747 001 900229 019 901079 001 806649 001 806649 002 807352 001 807351 001 900005 002 Revision C Component Description RACK PANEL ROLLER FOAM ROLLER DRYER LOWER BELT ENDLESS ROUND BEARING NYLON SNAP IN 25 SHAFT ROLLER DRYER UPPER E RINGSAE 375 SHAFT PIN SPIRAL ASSY FLANGED BEARING ASSY FLANGED BEARING 5 19 75 ROLLER FOAM RING GRIP Parts List Page 1 of 1 PRINTWARE Confidential PRINTWARE Confidential 1 STAMP OR OTHERWISE PERMANENTLY IDENTIFY ASSEMBLY WITH PART DASH AND CURRENT REV 12 INSTALL AFTER ITEM 2 L AF Y Printware ASSY TRANSPORT DRYER ROLLER 808228 001 REVISION C Sheet I of I Find Number 001 002 003 004 005 006 007 008 009 010 011 012 013 017 020 021 022 023 024 026 027 028 029 030 031 037 040 041 042 043 045 046 047 048 049 050 051 052 053 054 055 056 Quantity Component Used NW a L
76. AD SHOULDER 8 32 X 2505 SCREW SHC 8 32 X 50 SCREW SHC 8 32 X 5 8 NUT LOCK K 38 32 NUT LOCK 38 32 SCREW SHC 8 32 X 75 CLAMP FIXED DIA 25 SCREW PAN PPH 6 32 X 7 16 WASHER FLAT STEEL 6 RING GRIP NUT SELF LOCKING HEX 6 32 ASSY PUNCH CHIP COLLECTOR Parts List Page 1 of 2 PRINTWARE Confidential Assembly Number 807425 XXX ASSY PUNCH PS46 2 HOLE Revision C 060 2 900287 025 SCREW PAN PPH 6 32 X 1 25 061 1 807352 002 SHAFT 25 PRINTWARE Confidential OW DIM S NOTES LATEST REV CHG SWITCH ON SOLENOID SHOLD BE ROTATED 0 POSITION A ITEM 1 SHIPPED WITH 001 amp 002 N PKG amp LABEL ITEM 2 QTY 1 amp SHIP WITH 003 amp 004 ONLY GN 2 41 42 2 12 2 ORANGE 2x Printware ASSY PUNCH 2 HOLE BRIDGE 807425 XXX REVISION G PRINTWARE Confidential Sheet I of I Assembly Number 806817 001 ASSY TANK EFFLUENT WITH CART Revision E Find Quantity Component Component Number Used Number Description Parts List Page 1 of 1 001 1 806811 001 ASSY CART EFFLUENT 001 1 807083 001 ASSY CART EFFLUENT 002 1 8068 16 001 ASSY TANK EFFLUENT PRINTWARE Confidential ET gt s 2 Es T o os 4 y Ne S X Pd EN I A SS M 27 7 NG p _ lt a Ses Printware ASSY TANK EFFLUENT WITH CART 806817 001 REVISION D PRINTWARE Confidential Sheet I of 1 Find Number
77. AL ROD LATCH SCREW B H TORX 8 32 UNC X 375 ASSY CABLE FAN FILTER ASSY CABLE OUTLET PROC ASSY CABLE GOUND STRAIN RELIEF CABLE PLUG PLASTIC KIT CHASSIS 46 CM BUSHING GROMMET COVER FILTER FAN 96 ASSY CABLE FI GRD Parts List Page 1 of 2 PRINTWARE Confidential 157 161 162 163 164 165 166 167 168 170 171 173 179 184 185 186 188 192 193 194 198 200 201 202 203 204 205 206 207 208 DN NA WwW Wee Ke Q WwW O Rh DDB Assembly Number 808143 001 ASSY CHASSIS PLATESTREAM 46 806507 001 900429 001 900429 002 804677 001 900894 001 900172 017 900336 000 900160 004 900767 003 900233 803795 001 900160 005 900233 003 900774 002 900774 003 900774 006 900774 008 900047 002 900047 000 900224 002 900287 004 900069 002 807493 001 806835 001 806835 002 806835 003 806835 004 806835 005 806835 006 808197 004 Revision B PLATE CABLE RETAINING FAN GUARD ONLY FAN S P N 09362 G FAN RETAINER ONLY FAN S P N 09362 R MEDIA 3 5 8 FAN FILTER FAN AC 3610PS 23T B30 230V SCREW FLAT HD 6 32 X 2 NUT SELF LOCKING HEX 6 32 WASHER FLAT STEEL 6 GROMMETS VIBRATION ISOLATOR NUT LOCK K 6 32 BRACKET PUMP MOUTING WASHER FLAT STEEL 8 NUT LOCK 8 32 SEAL EMI CFOLD EA FT SEAL EMI CFOLD EA FT SEAL EMI 039 X 394 SEAL EMI 125 X 500 WASHER EXTERNAL LOCK 6 WASHER EXTERNAL LOCK 8 SCREW TAPTITE PPH 8 32 X 3 8 SCREW PAN PPH 4 40 X 50 SCREW LOCK KIT
78. Adjustthe cutter infeed guides 2 Adjust the cutter blade see procedures under Cutter cycles but doesn t cut SERVICE MANUAL IMAGER MODULE SENSOR PROBLEMS Guide B Sensor blocked 1 Guide B Sensor faulty SENSOR STATUS LOAD KNOB 0 FEEDLOOP 00 EXIT LOOP 0 IMAGER EXIT 0 NOMEDIA 00 LOAD OK 00 GUIDE B 0 ESC to exit WRKNG TANK LOW REPLN TANK LOW EFFL TANK HIGH PROC TEMP LOW PROC EXIT TAKEUP CASSETTE 0 1 1 0 0 0 Ensure that the cable harness under Guide A is plugged into the switch Check for any pieces of media that may be stuck in the punch Remove the rear panel and use a flashlight to see if there are any scraps of media in the punch cutter path If there is no media blocking the guide B sensor the switch may be damaged From the Operator Panel go to the Sensor Status menu to test the switch Open top cover Lift capstan guide arm and separate the capstan roller from the pinch roller on the exit side of the imager Push a piece of paper through these rollers and the center of the punch assembly over the switch The Sensor Status should toggle between 1 and 0 as you activated and deactivate the switch Current firmware will show a 1 when engaged and a 0 when disengaged Older firmware may show the opposite status numbers but will still toggle between them Move the paper over the switch several times while watching the sensor status to be sure the switch is
79. BLEMS Activator or Stabilizer rollers don t turn Processor drive motor jumping Processor noisy Replenishment pumps noisy Pull the rack out of the platesetter and check that the idler gears are meshing properly with the other gears Adjust gears if necessary Check the end play of rollers which should be approximately 0 010 to 0 020 0 25 to 0 5 mm Check for loose pulley or gear set screws Adjust worm gear drive to better mesh with other gears Check that the activator and stabilizer transport racks turn freely by hand Lower the drive motor to increase belt tension If motor cannot be moved lower shim the motor bracket away from the frame using the lock wash ers Order shim part 806741 001 Newer processor motor brackets have been redesigned and do not require the shim Squealing noise may be the pulley on the end of the worm gear Apply light oil or Teflon spray Motors generally make noise If too loud replace processor drive motor Check to see if the hoses coming from pumps are pinched Replace pumps 66 SERVICE MANUAL PROCESSOR SENSOR PROBLEMS Spurious low replenishment level error message Effluent probe not working Processor exit switch does not work 67 This problem is caused by faulty replenishment level probes 1 2 Check the probe connectors Check the cable Place one ohmmeter probe on replenishment probe and the other on the P2 cable Check both r
80. BeA Lo sc ESA band ESI bad Leal Bo keee Keal Gami kami kani kani basi bani bani kani kani bani ALALNTATATAT kor Karl Ksal kaal bud bod bud bud bud xu up TO INTERFACE PCA J12 CABLE 803311 003 AH SCHEMATIC PAGE 3 DRAWN x WMS 7 18 99 ENG PRINTWARE INC ENG APPVL DO NOT SCALE DRAWING ST PAUL MN MFG QA MATERIAL TOLERANCE UNLESS OTHERWISE ANGLES 1 PLACE DECIMAL 2 PLACE DECIMALS 3 PLACE DECIMAL 5 DEG FINISH 02 010 WIRING DIAGRAM PlateStream 46 COMM CODE Size 7 0 0 6 0 6 0 0 1 INSP VERSION REV FIRST USED ON B B This document and the information it contains is the property of Printware Inc and may not b E reproduced copied disclosed to others or disposed of directly or indrectly without authoriza SCALE NONE tion from Printware Inc Both the document and its contents are to be treated as confidential amp Sheet 3 of 7 proprietary and may not be used any manner not consistent with the rights of Printware Inc 5 6 1 2 3 4 5 6
81. E 13 4 248 zB 12 6 i YELLOW I 3 ACIN SWITCH T 15 GREEN is BLACK FILTER CIRCUIT BREAKER E PIN ASSIGNMENTS 16 BLUE 16 1 240 BROWN s 240 VAC kar CORCOM N I a FROM BACK OF P S DRAWER VIOLET 50 60 HZ x REN E 5 18 GRAY 18 5 220 6 i me 19 WHITE 19 11 S06420 TAB DANN BLUE 0 27 BLACK 27 4 WHITE T 2 900813 001 600267 002 GREE CABLE 806503 001 GREEN GROUNDS TO MOUNTING SCREW PLUG FOR POWER SUPPLY GREEN El AK GROUND STUD IN BOTTOM OF CHASSIE CABLE 806462 001 z Bla dalla 120 lel CABLE 803312 003 3a IEEE CIEE ERIE ISLE 8 118511355 _ 803118 001 BROWN I a BROWN on Lm E vu NGINE STEPPER PCA i ANG FD STEP ANGI sur pe 2 YELLOW GND YELLOW 523190 004 wae corres 1 DRAWER 3 BLACK 7 GREEN FD RESET GREEN T YELLOW 5 BLUE FD RESET BLUE J1 NU 3 BLACK 6 VIOLET GND VIOLET 4 6 BLUE 7 GRAY TR STEP GRAY 14 BLACK 8 WHITE TR STEP WHITE FEED STEPPER 5 5 BLACK GND BLACK 803666001 J NE MR Sr En SCHEMATIC PAGE 5 RED TR RESET RED GR TERFACE Y ORANGE GND ORANGE 303323002 E 523060 001 YELLOW EX STEP YELLOW 1 BLACK 1 WHITE BLU 51 um mms Sum peo py GND y E VIOLET EX RESET VIOLET 3 WHITE Da BLACK GND SCHEMATIC PAGE 4 GRAY EX RESET
82. E UNLESS OTHERWISE Q ANGLES 5 DEG I PLACE DECIMALS EM FINISH 2 PLACE DECIMALS 02 S 3 PLACE DECIMALS 010 Title E WIRING DIAGRAM PlateStream 46 Z COMM CODE Size 7 0 0 6 0 6 0 0 1 INSP VERSION REV 2 FIRST USED ON B B This document and the information it contains is the property of Printware Inc and may not b E reproduced copied disclosed to others or disposed of directly or indrectly without authoriza SCALE NONE tion from Printware Inc Both the document and its contents are to be treated as confidential amp Sheet 7 of 7 N w 3 6 Plate tream 46 Platesetter Illustrated Parts List Printware LEADERS IN COMPUTER TO PLATE Find Number 001 002 002 003 003 Quantity Component Used Assembly Number 808340 ASSY PLATESTREAM 46 Number 808341 001 808 145 001 808 145 002 806420 001 806420 002 Revision C Component Description Parts List Page 1 of 1 ASS Y IMAGER PLATESTREAM 46 ASSY MARKER IR ASSY MARKER RED ASSY CABLE POWER DOMESTIC ASSY CABLE POWER INTERNATIONAL PRINTWARE Confidential s 2 PRINTWARE Confidential xS Printware ASSY PLATESTREAM 46 808340 XXX REVISION C Sheet I of I Find Number 001 002 004 005 006 009 010 013 014 015 016 017 018 020 022 022 023 024 025 026 027 029 030 031 033 034 035 035 036 037 038
83. ES PANEL PCA BOARD SCREW STAINLESS 10 24 X 500 BLOCK SUPPORT SWITCH SCREW STAINLESS TAP FORM 10 32 X 50 SCREW STAINLESS 10 24 X 375 PILLIPS PAN HEAD WASHER SPRING LOCK STAINLESS NUT STAINLESS 10 24 LOCKNUT SCREW STAINLESS 1 4 20 X 500 WASHER SPRING LOCK STAINLESS GROMMET SCREW SCREW STAINLESS 4 40 X 625 SCREW STAINLESS 8 32 X 375 PHILLIPS PAN HEAD WASHER FLT STNLS 8 SCREW STAINLESS 8 32 X 500 PHILLIPS PAN HEAD NUT STAINLESS 8 32 LOCKNUT SCREW STAINLESS 10 32 X 5 PHILLIPS PAN HEAD STANDOFF TURN WASHER FLAT STAINLESS BRKT RACK LOCATING ASSY AIR HOOD ASSY TRNSRT DRYER ROLLER FOAM 15 ASSY CROSSOVER GUIDE ASSY ENTRANCE GUIDE ASSY RACK COVER ASSY TUBE OVERFLOW BRACKET PROCESSOR HEATER HEIGHT BRACKET PROCESSOR HEATER HEIGHT TUBING POLYVINYL CHLORIDE 1 1 4 X 1 BRKT COVER ADJUST WASHER SPRING LOCK STAINLESS 8 PRINTWARE Confidential Sheet I of 5 m e Z e I 2 um En Q Q Q Fey GEN KO A SERE Re mt va A N _ asi Ps x 4 NN e JN 5 a eS N X ZN 7 p AN NT oo PRINTWARE Confidential 27 APPLY ALONG EN Printware ASS Y PROCESSOR PLATESTREAM 46 8081 55 001 REVISION E PRINTWARE Confidential Sheet 2 of 5 P diis ES gt lt A ree o DEEP GROOVE THIS SIDE x LER Sa Pa ON N h bow So aad 7 SN a la ENE gt S P
84. IA ONI SENSOR NO ORANGE NO MEDIA GND smod 506099001 vare YELLOW LOAD OK 35 TOAD OK 5 SHUTTER wi GREEN LOAD OK SIG SENSOR NO R 806789 001 SOLENOID WHITE AN RANGES 1 BLUE LOAD OK GND 7 WHITE U SHUTTER DRV WHITE 2 VIOLET TOAD KNOB 57 807091 001 BLACK WHITE 4 ay ORANGE 3 TOAD KNOB EXIT SWITCH Ti Ge a EJ 600333 001 NU CABLE SOLENOID 807091 001 lt LAK TT LASSET EXIT CASSETTE USED ONLY 6 NU 806376 001 EON EXIT CASSETTE SIG SET Eno J6 NU 06788 01 BROWN WORKING TANKS LOW BROWN 1 ORANGE 807091 001 WHITE RED GND RED 2 TELA DH TEM SENSOR E a aa EA 2 1 BLUE 600330 001 GREEN EFF TANK HIGH GREEN 5 17 VIOLET Loop 5v BLUE GND BLUE 6 a q EXITLOOP gt GRAY EX LOOP SIG SENSOR NO VIOLET PROC TEMP VIOLET 7 ware BE SENSOR GRAY GND GRAY BLACK FEED LOOP 45V 807091 001 EN B 06534 WIRING CHANGE PAGE 6 48 W M S 9 1 99 WHITE FILM EXIT WHITE 9 BROWN FEED LOOP SIG ELEASE 202 IL BRO FEED LOOP SIG SENSOR NO A 06490 INITAL RELEASE WMS 7 9 99 BROWN SPARET BROWN il ORANGE 801091001 REV ECO DESCRIPTION DRAWNBY DATE APPVL DATE V RED GND RED 17 T YELLOW DRAWN WMS 72 99 ORANGE 5V PULLUP ORANGE 1 332 BY 8 2 CABLE 803321 001 Y BIW sor m 4 BLUE l ve PRINTWARE IN C 3l UI Gl VIOLET dl PPVI ACT TEMP PROBE RED BLUE DRIVE INH BLUE 16 POWER 2 SR NE Z APNL SEREDI BLACK VIOLET
85. IFIEI S DEG FINISH 02 010 3 PLACE DECIMALS Title SROUNDS TO MOUNTING SCREW WIRING DIAGRAM PlateStream 46 GREEN COMM CODE Size INSP VERSION REV CABLE 806462 001 FIRST USED ON B 700606 00 1 B This document and the information it contains is the property of Printware Inc and may not b E S CHEMATIC PAGE 2 reproduced copied disclosed to others or disposed of directly or indrectly without authoriza SCALE NONE tion from Printware Inc Both the document and its contents are to be treated as confidential amp Sheet 2 f 7 proprietary and may not be used any manner not consistent with the rights of Printware Inc 9 1 2 3 4 6 1 2 3 4 9 6 CABLE 803314 001 1 2 1 BROWN NC V 1 J1 NU 2 RED PRN GND 20 CABLE 3 ORANGE NC 2 803319 002 KIT 807117 001 IR YELLOW PRN GND 21 KIT 807117 002 RED 5 GREEN NC 3 RED V 5V 1 6 BLUE PRN GND 22 POWER SUPPLY BLACK GND 2 7 VIOLET NC 4 DRAWER RED 45V 3 8 GRAY PRN GND 23 BLACK GND 4 9 WHITE NC 5 807046 001 YELLOW 12V 5 CONTROLLER PCA 10 BLACK PRN GND 24 BLACK GND 6 11 BROWN PIX ENBL 6 BLUE 12V 7 522980 001 IR 12 RED PIX ENBL 25 BLACK GND 8 522980 002 RED 13 ORANGE PIX CLK 7 ORANGE 424V 9 14 YELLOW PIX CLK 26 JA BLACK GND 10 15 GREEN PRN DO 8 16 BLUE D0 27 17 VIOLET PRN DI 9 18 GRAY PRN DI 28 19 WHITE PRN D2 0 INTERLOCK PWR 1 20 BLACK PRN D2 29 TO
86. IGIPLATE INFRA RED PLATE MEDIA Emulsion In Emulsion Out 5 mil paper SDP RD125 SPEC28 SPEC28R 7 mil paper SDP RD175 SPEC 28 SPEC28R 4 mil polyester SDP FD100 SPEC 820 SPEC820R 7 mil polyester SDP FD175 SPEC 820 SPEC820R CHEMISTRY ACTIVATOR SLM AC STABILIZER SLM ST 5 3 RED LIGHT PLATE MEDIA Emulsion In Emulsion Out SDP RR125 SPEC28 SPEC28R SDP RR175 SPEC28 SPEC28R SDP FR100 SPEC820 SPEC820R SDP FR175 SPEC820 SPEC820R SUPPLIES Tips on Supplies To get the best performance from your Platesetter follow these guidelines for storing and handling supplies Plate Media Handle imaging media by the ends Avoid excessive touching of the surface of the media Store media rolls upright on end not on their sides prevent the crushing of media avoid placing other objects on top of the media rolls Store all media as recommended by the manufacturer Plate material will absorb moisture in humid environments and lose moisture in dry environments which will affect print quality However the plate material may not be permanently damaged Improperly stored plate material will recover if stored for an extended period with the bag open in ideal humidity conditions For optimum print quality use only recommended media Do not load media that is wrinkled or torn Processing Chemistry Use only recommended processing chemistry Carefully follow all label instructions for mixing and use After use
87. INTERNATIONAL HOUSING SUPPLY CASSETTE DOMESTIC ASSY END CAP LH INTERNATIONAL ASSY END CAP LH DOMESTIC ASSY END CAP RH INTERNATIONAL ASSY END CAP RH DOMESTIC COVER SUPPLY CASSETTE STRIP RETAINING FLEECE SCREW SOCKET FLAT HEAD UNC 4 40 X 5 8 GASKET LIGHT SEAL SEAL EMI FOLD SCREW SOCKET HEAD SHOULDER 8 32 X 312 ASSY GROUNDING SPRING NUT LOCK 6 32 BRACKET GROUND DOMESTIC BRACKET GROUND INTERNATIONAL BRACKET GROUND WASHER EXTERNAL LOCK 8 SCREW PAN PPH 8 32 X 38 WASHER EXTERNAL LOCK 6 SCREW B H TORX 6 32 UNC X 375 FOAM SELF ADHESIVE WASHER FLAT STEEL 8 SCREW SET CUP POINT 6 32 X 375 SHEET PLASTIC ADHESIVE 21 1 Parts List Page 1 of 1 PRINTWARE Confidential TAB BLOCK 808243 001 DOMESTIC 808243 002 INTERNATIONAL ES 2 J A e Printware ASSY CASSETTE SUPPLY 280 808243 XXX REVISION E Sheet I of PRINTWARE Confidential
88. L DRIVE FRAME DRIVE DRYER BUSHING GROMMET ASSY CABLE P3 TO J14 MOUNT TIE ANCHOR NYLON TIE NYLON ASSY DRAIN CLAMP HOSE SWITCH WIRE FORM SWITCH SNAP LEVER DUCT VERTICAL ASSY STABILIZER TRANSPORT ASSY STABILIZER TRANSPORT ASSY ACTIVATOR TRANSPORT ASSY ACTIVATOR TRANSPORT ASSY ACTIVATOR TANK ASSY STABILIZER TANK RAIL LEFT MOUNT TIE ASSY CABLE ACTIVATOR STABILIZER LEVEL ASSY CABLE INTERFACE CLIP CORD ADHESIVE SENSOR THERMISTOR DISK SHIM SUPPORT RACK PROCESSOR ASSY HEATER COVER ASSY HEATER BLOWER ASSY CABLE DRYER TEMPERATURE PROBE ASSY CABLE FILM SWITCH ASSY CABLE REPLENISHMENT LEVEL PCA DIGIPLATE PROCESSOR Parts List Page 1 of 2 PRINTWARE Confidential 044 045 046 047 048 050 051 052 053 054 055 056 057 059 060 062 064 065 067 068 069 074 075 076 077 079 089 102 103 105 106 107 ON FN DR FN RF RF 000 O O L L Assembly Number 808155 001 ASSY PROCESSOR PLATESTREAM 46 806708 001 806703 001 900271 003 806739 001 900967 010 806750 001 901089 004 900967 003 901072 005 900968 005 900967 006 901072 006 901092 001 900967 007 900967 001 901071 010 900967 005 900968 001 900967 019 901091 001 901071 012 807394 001 807313 001 808228 001 806848 001 806707 003 806657 002 806706 004 806410 002 806410 001 901100 002 807487 001 901072 004 Revision G ASSY ELECTRICAL PANEL ASSY DRIVER MOTOR BELT TIMING 1 5 PITCH 60 GROV
89. NLESS TAP FORM 10 24 X 75 FITTING COMPRESSION HEATER BLANKET PRINTWARE Confidential PRINTWARE Confidential SEE NOTE 1 E 3 504 12 4 FE DIGI AN 1 L u L 1 0 THIS SIDE ai SEE NOTE 3 IN lt Printware ASS Y ACTIVATOR TANK 806701 001 REVISION D Sheet of 1 Find Number 001 002 003 004 e m Assembly Number 806702 001 ASSY STABILIZER TANK Quantity Component Used Number 806734 001 806774 001 90029 1 009 901089 003 Revision C Component Description Parts List Page 1 of 1 TANK STABILIZER FITTING DRAIN O RING SCREW STAINLESS TAP FORM 10 24 X 75 PRINTWARE Confidential Printware ASSY STABILIZER TANK 806702 001 REVISION Sheet of I PRINTWARE Confidential Find Number 001 002 003 004 005 006 007 008 009 011 012 013 014 017 018 019 020 021 022 023 027 028 Quantity Component Used N N OR O A e e e Q Assembly Number 806708 001 ASSY ELECTRICAL PANEL Number 806736 001 900040 003 806795 001 806796 001 806797 001 900289 003 806810 001 806782 001 806783 001 806826 001 806798 001 900967 004 900968 003 900967 005 901076 003 900338 002 900053 002 806827 001 80682
90. NTWARE Confidential 1 0 OP SIDE SEE NOTE 1 J y J FEE J J Y 7 y 2 Printware ASSY STABILIZER TRANSPORT 807328 001 REVISION PRINTWARE Confidential Sheet 3 of 3 Find Number 001 002 003 004 005 006 007 008 009 010 011 012 013 015 016 020 021 022 023 024 025 026 027 029 032 033 034 035 036 037 038 039 040 041 042 Quantity Component Used 1 12 6 ow N N NNN NFP NNA Q tA G ON FN o Bee ee Assembly Number 807327 001 ASSY ACTIVATOR TRANSPORT Number 807329 001 900960 004 900960 003 806752 001 900960 001 900229 017 806776 001 900960 020 900229 018 807330 001 806694 001 806764 001 806852 001 806821 001 806836 001 806760 001 806762 001 900291 010 900967 001 901072 004 901071 013 900967 003 901072 005 901089 001 806278 001 806510 001 806506 001 806822 001 900319 004 901070 001 806819 001 806695 001 900773 001 900968 005 900215 007 807225 004 Revision Component Description PLATE ACTIVATOR FRONT BEARING ROLLER GEAR ASSY GEAR SHAFT IDLER GEAR SPUR E RING SAE 25 SHAFT STUD GEAR GEAR SPUR E RING SAE 312 SHAFT PLATE ACTIVATOR REAR SPRING EXTENSION BRKT DRIVE RACK ASSY CLUTCH WORM GEAR SHAFT DRIVE RACK ASSY PROCESSOR GUIDE HANDLE RACK ROLLER TRANSPORT O RING SCREW STAINLESS 8 32 X 375 PHILLIPS
91. NUAL MEDIA JAMS Imager Module Media will not load past Guide B Media gets dog eared before going into cutter Media buckles in feed section Guide A Media jams in Guide B machine produces 3 5 media strips Media jams in cutter 57 1 If the corner of the media is being dog eared before going into cutter inspect shutter for prob lems 2 Update Shutter assembly with teflon tape 1 Verify that the shutter plate isn t hitting the capstan roller To adjust loosen screws on the outside of the transport on the operator and non operator side Adjust the shutter plate to 1 32 to 1 16 0 8 to 1 6 mm from the capstan roller 2 Adjust the moveable shutter arm farther out 3 Ifthe media is stubbing on the shutter upgrade with a shutter assembly with Teflon tape on the shutter Verify that edge guides are aligned with spool see Operator Guide for loading procedure Check adjustment of Feed Loop Switch Verify that feed rollers are turning Verify that feed are backing up Check that marker transport belts aren t slipping Adjust Marker Transport motor speed Os let 1 Check for small pieces of media stuck near the cutter NOTE This problem is often reported after an error message prompts the user to cut a plate If the cut plate is not removed Guide B jams can result Current firmware prompts the user just to back up and not cut after certain errors 1
92. O TUBING SLIT 1 00 WASHER LOCK HELICAL SPRING 3 8 REG FEET ROUND 8 ROUND HEAD SCREW PAN PPH 6 32 X 75 WASHER NYLON 6 X 062 THK BUSHING SPACER NYLON 6 32 X 375 PANEL FLAT GUARD I O CABLE COVER POWER SWITCH NUT HEX UNC 3 8 16 WASHER FENDER 2 000 X 438 X 156 BOLT HEX HD UNC THREAD 3 8 16X2 3 4 ISOLATOR WR4 060 ISOLATOR WB4 060 Parts List Page 1 of 2 PRINTWARE Confidential 051 052 053 054 055 056 058 059 063 075 076 080 082 083 084 085 087 088 091 093 094 095 096 097 098 114 115 116 N e a a ss a a a QN ss ss ha N EE 00 Assembly Number 808341 001 ASSY IMAGER PLATESTREAM 46 900288 002 900652 007 900651 003 900233 001 900726 001 900726 005 901124 100 901124 200 901041 002 808185 001 808185 002 901143 001 901062 001 806474 001 806473 001 900224 002 806501 001 600188 003 600292 001 804521 001 600306 002 806719 007 807312 001 806719 008 807312 003 806882 001 806825 001 901041 002 Revision B SCREW PPH 10 32 X 2 SPACER ROUND 10 X 5 8 WASHER FENDER 1 375 X 192 X 048 NUT LOCK 10 32 ISOLATOR WR3 030 RING ISOLATOR WB3 030 BUSHING CONTAINER SHIPPING IMAGER CONTAINER SHIPPING PROCESSOR TANK PLASTIC 5 GAL STRIP TRIM STRIP TRIM CONTAINER ACCESSORY TUBING MAILING GUARD CAPSTAN DRIVE GUARD CAPSTAN PULLEY SCREW TAPTITE PPH 8 32 X 3 8 ASSY CABLE INTERLOCK PROC STRAIN RELIEF CABLE SWITCH DOOR ASSY CABLE INTERLOCK JUM
93. OCK 600267 002 CIRCUIT BREAKER DOUBLE POLE 803334 001 ASSY CABLE BRK BLK 04149 001 C ASSY CABLE FIL 3RO 1 amp 900813 001 FILTER RFI K SERIES M C 900233 000 6 32 K NUT BROWN GREEN BLUE lt 600320 001 OUTLET 16 20A IEC 320 QA BLUE BROWN GREEN NE 806461 001 ASSY CABLE OUTLET PROC V 200894 001 AN AC 184 BLUE BROWN A 808504 001 ASSY CABLE FAN FILTER 136 LINE BLACK BROWN B NEUTRAL WHITECBLUE gt GNO GREENCGREEN YELLOW 806420 TAB ASSY CABLE PUWER 900233 000 6 32 K NUT PRINTWARE Confidential pi GREEN GROUND MTG SCREW GREEN oon STUD BOTTOM CHASSIS 808153 001 BROWN BLUE BROWN GREEN GND TO MARKER TRANSPORT FRAME 806919 001 OR 808205 001 806462 001 ASSY CABLE GND gt i38 806503 001 ASSY CABLE FIL GND isi Printware ASSY CHASSIS PS46 8081 43 001 REVISION B Sheet 7 of 7 Find Number 001 002 003 004 005 006 007 008 009 010 011 012 013 014 015 016 017 020 021 022 023 024 025 026 027 028 029 030 031 032 033 034 035 036 037 038 040 041 042 043 044 Quantity Component Used ON GO ON N
94. OLLER TRANSPORT PLATESTREAM 46 808344 XXX REVISION D Sheet I of 4 qn ASSEMBLY C ASSEMBLY F Printware ASSY ROLLER TRANSPORT PLATESTREAM 46 D 808344 XXX REVISION R rs un lt Ze En 5 uE gt lt EB 3 Ts 28 oa 8 NS Sheet 2 of 4 PRINTWARE Confidential ASSEMBLY ASSEMBLY ASSEMBLY H 2 Printware ASSY ROLLER TRANSPORT PLATESTREAM 46 808344 XXX REVISION D Sheet 3 of 4 ASSEMBLY I PRINTWARE Confidential ASSEMBLY S ASSEMBLY 2 PLACES E 2 2d 184 OY EN ASSEMBLY 0 ASSEMBLY Q 2 PLACES Printware ASSEMBLY P 2 PLACES ASSY ROLLER TRANSPORT PLATESTREAM 46 9 ASSEMBLY T 808344 XXX REVISION D PRINTWARE Confidential Sheet 4 of 4 Find Number 001 002 003 004 005 006 008 009 010 011 012 013 014 015 016 018 019 020 021 022 023 024 025 026 027 030 031 Quantity Component Used ON WN NV OO QN Y QU RI NNOO FN RR RRR gt pa Assembly Number 804627 001 ASSY CAPSTAN DRIVE Number 804370 001 804357 001 804356 001 804358 001 804355 001 804354 001 803391 001 804359 001 900800 001 90078 1 008 804628 001 900767 001 900296 900229 001 900340 900235 013 900047 002 9002
95. ON SNAP IN 188 SHAFT Parts List Page 1 of 1 PRINTWARE Confidential 11 OPPOSITE SIDE SEE NOTE 1 Printware ASS Y CAPSTAN GUIDE 808152 001 REVISION PRINTWARE Confidential Sheet I of I Find Number 001 001 002 003 004 005 Quantity Component Used N N e Assembly Number 807363 001 ASSY BELT TENSIONER Number 807358 001 808238 001 900406 002 900236 021 901187 002 807433 001 Revision D Component Description Parts List Page 1 of 1 BRACKET BELT TENSIONER BRACKET BELT TENSIONER BEARING OIL LESS BRONZE SCREW SOCKET HEAD SHOULDER 10 32 X 312 BELT TIMING DOUBLE SIDED PULLEY IDLER PRINTWARE Confidential p S lt cen EN a cen Printware ASSY BELT TENSIONER 807363 001 REVISION D PRINTWARE Confidential Sheet I of I Find Number 001 002 003 004 005 006 007 008 009 010 011 012 013 014 015 016 017 019 020 021 022 023 025 026 027 028 029 030 031 032 033 034 035 036 037 038 039 040 041 Quantity Component Used Lm mL Lm NR GU N N Bb Ou tA n j y YF Assembly Number 806882 001 Number 806884 001 806883 001 806353 001 807215 002 807216 002 806355 001 806352 002 806354 002 806877 001 806947 001 900237 000 900235 041 807191 001 900566 003 900236 005 900277 004 807513 001 900774 005 900963 002
96. OOP GND 8070912001 5 FILM EXIT WHITE 9 23 ORANGE NU TO 18 GND BLACK 10 24 YELLOW NU PRAWN WMS 7 17 99 6 SPARE BROWN 1I 25 GREEN NU PROCESSOR 19 GND RED 12 26 BLUE NU ENG PRINTWARE INC 7 5V PULL UP ORANGE 13 27 VIOLET NU BS 20 SOJ YELLOW 14 28 GRAY NU gt li cas ST P AUL MN 8 5V PULL UP GREEN 15 29 WHITE NU 2 DRIVE INH BLUE 16 30 BLACK NU QA MATERIAE 0 5V PULL UP VIOLET 17 31 BROWN IMAGER EXIT 1 5V TOLERANCHUNCESS OTHERWISE 22 RESET GRAY 18 SENSOR A ANGLES BEES WHITE l 807091 001 I PLACE DECIMALS us FINISH 23 PUMP PRIME BLACK 20 34 YELLOW NU cl z II 5V PULL UP BROWN 21 35 GREEN NU el AEDES P 24 SPARE RED 22 36 BLUE NU 9 mie 37 VIOLET GUIDE B 45V 25 LOW QUE GUIDE B SIG wm E WIRING DIAGRAM PlateStream 46 13 GREEN 25 39 WHITE GUIDE GND s NC BLUE 56 NU J13 40 BLACK NU 807091 001 s COMM CODE Size 700606 001 INSP VERSION REV A FIRST USED ON B B 2 1 1 1 1 SCHEMATIC PAGE 4 This document and the information it contains is the property of Printware Inc and may not bi reproduced copied disclosed to others or disposed of directly or indrectly without authoriza tion from Printware Inc Both the document and its contents are to be treated as confidential amp proprietary and may not be used in any manner not consistent with the rights of Printware Inc SCALE NONE Sheet 4 of 7
97. OWN l6 o AD 522780 1 RED PRN RW 5 UTRAI 8 RED 1 2 GREEN G 1 3 ORANGE STRE 715 EE AER YELLOW 3 GALVO ASSY WHITE G SENSE 7 31 YELLOW PRN STRET 36 GROUND 2 BLACK z SCMEMATIC PAGE 7 GREEN GDRVIS 3 35 GREEN PRN ACK Gots 13 BLUE 5 RED G DRVO 3 36 BLUE 37 S 12V FUSE 6 BLACK G SENSE 5 37 VIOLET PRN GND 19 RED G DRVI 5 38 NC te 807049 001 39 NC 12V FUSE m J5 40 NC AC POWER COVER RED sos c FE SENSOR ASSY GREEN SOS SIG 2 WHITE SOS REF 3 2 DC POWER RED Sore SCHEMATIC PAGE 2 me m 4 1 WHITE SOT SIG 5 NU J16 mr WIRECOLOR VOLTAGI LIQUID CRYSTAL DISPLAY 2 807151 001 LL RED i n xor 3 2023 YELLOW V XDO Oooo YD 5 WE 6 7 gt E XSCL E 2 5 GROUND 357 3 3 GREEN CHASIS GND m NU J2 H E GREEN CHASISEGND m 6 VENTFAN B H PLUG MOUNTS TO BACK OF POWER SUPPLY ASSY LCD 802533 FE 900894 001 806504 001 ASSY CABLE FAN FILTER 5 5 1 BROWN il 2 RED 2 1 GREEN GREEN KEYPAD x 1 3 ORANGE 3 BLUE 523180 001 X67 B YELLOW BLUE BROWN Xs 3 GREEN 5 1 5 5 Xi i BLUE f BROWN XT 5 VIOLET 4 FAN MOUNTS TO FRAME mr 7 XT 3 3 GRAY 3 1 NOTTO COVER z xis 7 9 WHITE 9 4 10 4 xs 10 BLACK 10 CABLE 803311 003 9 Yor 9 i BROWN 11 4 Els Yr 10 12 RED 12 4 s 10 YO 13 ORANG
98. PAN HEAD WASHER SPR LK STNLES 8 WASHER FLT STNL 10 SCREW STAINLESS 10 24 X 375 PHILLIPS PAN HEAD WASHER SPRING LOCK STAINLESS SCREW STNLSS TAP FORM 10 24 X 1 ROLLER SQUEEGEE POLISHED ROLLER PROCESSOR ASSIST GUARD PROCESSOR SPLASH ROD SUPPORT BEARING NON METALLIC FLANGED SCREW SET STAINLESS 8 32 X 250 GEAR MOD COLLAR GEAR COLLAR SHAFT NUT STAINLESS 10 24 LOCKNUT WASHER NYLON 1 4 5 LABEL ACT Parts List Page 1 of 1 PRINTWARE Confidential 4 S 34 2 PLCS 527 One Printware ASS Y ACTIVATOR TRANSPORT 807327 001 REVISION C PRINTWARE Confidential Sheet I of 3 PRINTWARE Confidential Printware ASSY ACTIVATOR TRANSPORT 807327 001 REVISION Sheet 2 0f 3 NOTE 1 4 WRAP ITEM 11 AROUND BOTH BEARINGS 2 PLCS WRAP ITEM 11 AROUND BOTH BEARINGS 2 PLCS 42 1 0 OP SIDE pS E fS o Printware und ASSY ACTIVATOR TRANSPORT 807327 001 REVISION C Sheet 3 of 3 PRINTWARE Confidential Find Number 001 002 003 004 005 007 Quantity Component Used Rh e Assembly Number 806701 001 ASSY ACTIVATOR TANK Number 806735 001 806774 001 900291 009 901089 003 901083 001 600335 001 Revision D Component Description Parts List Page 1 of 1 TANK ACTIVATOR FITTING DRAIN O RING SCREW STAI
99. PER CABLE ACCESSOR Y MALE IEC ASSY TUBE ACT 18 ASSY TUBE STAB 11 00 ASSY TUBE ACT 30 ASSY TUBE STAB CUT 30 00 ASSY SHROUD FAB PAD RACK TANK PLASTIC 5 GAL PRINTWARE Confidential PRINTWARE Confidential 2 Printware ASSY IMAGER PLATESTREAM 46 808341 001 REVISION B Sheet I of 3 e ATA DN a ND GN ATA Paes cu p FASTEN PROCESSOR COVER 47 pu ym Y ce NN GT L CUTOUT INTERLOCK BR __ 5 ON TERMINAL TSI WIRING Printware ASS Y IMAGER PLATESTREAM 46 LOC Saag Bl T WIRT INTER 808341 001 REVISION B EN 3s as 4 Bj e 18 ay JRB 2 CDa ad Sheet 2 of 3 PRINTWARE Confidential Printware ASSY IMAGER PLATESTREAM 46 808341 001 REVISION B PRINTWARE Confidential Sheet 3 of 3 Find Number 001 003 004 005 006 007 008 010 011 012 013 015 019 021 022 023 032 033 034 035 036 038 039 089 093 094 095 096 112 115 116 117 127 136 137 138 139 141 142 143 150 151 Quantity Component Used Rh N A e A Ne OLN e Ne e A A N Q po o p
100. PlateStream A Platesetter 9 Click on desired manual Quick Start Guide Installation Guide Operator Manual Service Manual Illustrated Parts List Printware LEADERS IN COMPUTER TO PLATE 1270 Eagan Industrial Road St Paul MN 55121 Phone 800 456 1400 Fax 651 454 3684 http PrintwareInc com Plate tream 46 Platesetter Quick Start Guide Printware LEADERS IN COMPUTER TO PLATE 700578 Rev E QUICK START GUIDE Contents Introduction Loading Plate Material Control Panel Setup Menu RIP Setup amp Imaging Plates QS 2 QS 2 QS 3 08 4 QUICK START GUIDE Introduction For detailed procedures on the control panel plate media and chemistry preventive maintenance and trouble shooting see the PlateStream 46 Operator Manual Before making a plate the Platesetter must be Connected to the RIP the I O panel is located on the bottom rear of the machine Ready to accept a job Main Menu displayed on the control panel On Line state no error conditions The processing tanks must be filled to proper levels Loading Plate Material 1 Open the platesetter top cover Raise the marker by pulling the marker lever towards the front of the platesetter until the lever stops Lift up the marker gently 2 Pull out the load knob on the left side of the platesetter From inside the platesetter adjust the two rear edge guides by pulling the edge guide knobs up and sliding to the position clo
101. QUALITY PROBLEMS ARTIFACTS Media trailing edge wet Some residual chemistry on the media trailing edge is normal If excessive however follow these steps 1 Verify that the stabilizer tank level is not too high and that the stabilizer tube is pushed all the way down Check the springs on stabilizer rack squee gee rollers Replace if stretched out Clean squeegee rollers with D Ink and rinse with water Increase dryer hood temperature potenti ometer R43 instructions on end panel Recommended temperatures are as follows setting dryer hood temperature too low can result in wet plates too high a temperature can result in media curl Thin paper 100 F 38 C Thin poly or thick paper 110 F 43 C Thick polyester 120 F 49 C PCA Screws Blower Heater Element Drive 2225 Motor 39 9 Processor PCA 2 N PROC EXIT Switch R42 R43 H Processor adjustments right side panel 64 SERVICE MANUAL PROCESSING QUALITY PROBLEMS ARTIFACTS cont Brownish looking plates 1 Check the activator and in silver areas dryer temperatures 2 Clean the rollers 3 Change processor chemistry 4 Increase the replenishment rate Yellow stabilizer stains 1 Decrease dryer temperature Dirty roller marks on plates 1 Clean the rollers 2 Change processor chemistry 65 SERVICE MANUAL PROCESSOR MECHANICAL PRO
102. RING OIL LESS BRONZE DB1122 SHAFT MARKER 5 BEARING MODIFIED SELF ALIGN SPACER SHAFT INNER 1 2ID X 1 16 SPACER 171 ID 25 OD 25 HT PULLEY DUAL CAPSTAN PIN DOWEL SST 1250 DIA X 625 LG SHAFT DRIVE LINKAGE ASSY CAPSTAN GUIDE BRACKET CABLE MTG PLATE CLAMP BRACKET UNLOAD ROLLER FEED PLATE TORQUE WASHER LOCK HELICAL SPRING 8 REG PRINTWARE Confidential 166 170 171 172 173 174 175 177 178 181 182 184 185 186 187 188 189 193 194 195 198 199 206 209 250 251 253 254 262 263 264 265 267 268 269 270 271 273 274 275 276 277 278 279 NN NN NRK NK QN FN A e DK HR o 12 12 82 10 10 20 10 38 21 12 Assembly Number 808344 XXX 900235 005 808219 001 900276 007 900236 009 900236 900275 003 900222 002 900324 001 900235 035 803456 001 900406 002 803713 001 900235 001 900229 003 901024 001 804703 001 804704 001 900319 002 803697 001 806304 001 900235 007 900566 001 900223 000 900160 009 900233 900229 009 900229 008 900236 008 900287 017 900233 002 900445 006 900047 000 90026 1 004 900875 002 900958 001 900839 002 900277 023 900277 029 900566 003 900172 002 900160 005 900233 003 900235 000 900235 005 ASSY ROLLER TRANSPORT PLATESTREAM 46 Revision D SCREW SHC 8 32 X 38 PLATE UNLOAD ARM WASHER NYLON WEAR 189 ID X 410 OD SCREW SOCKET HD SHLD 10 32 X 1880 SCREW SOCKET HD SHLD 8 32 X 188 SPRING TORSION LT045H 4L N
103. RIP INTERLOCK ASSY I2V 2 21 BROWN PRN D3 I NC 3 22 RED PRN D3 30 806307 002 23 ORANGE PRN D4 2 24 YELLOW PRN D4 3l 25 GREEN PRN D5 3 26 BLUE PRN D5 32 RED LASER 1 27 VIOLET D6 4 USER ASSY BLACK GND 2 28 GRAY D6 33 803280 001 IR BLUE 12V 3 29 WHITE PRN D7 5 807220 TAB RED BLACK GND 4 30 BLACK PRN D7 34 BROWN PHOTODIODE 5 FIRMWARE 076 CONTROL HARDWARE 31 BROWN PRN R W 6 BLACK GND 6 U43 PIXEL RATE 32 PRN R W 35 U196 ENGINE PROCESSOR 33 ORANGE PRN STRB 7 U199 SCAN PROCESSOR 34 YELLOW PRN_STRB 36 35 GREEN 8 36 BLUE 37 GREEN G DRV0 1 37 VIOLET PRN GND 9 GALVO ASSY WHITE G SENSE 2 38 NC GREEN G DRVI 3 39 NC RED G DRVO 4 40 NC BLACK G SENSE 5 RED G DRVI 6 807049 001 RED SOS 1 1 SENSOR ASSY GREEN SOS SIG 2 2 WHITE SOS REF 3 3 RED SOT C 4 NU J16 1 WHITE SOT SIG 5 5 GRAY SOT REF 6 6 807151 001 1 1 2 2 3 3 3 J3 NU NU J2 5 5 6 6 TO OPERATOR PANEL PCA J2 BROWN RED ORANGE YELLOW GREEN BLUE GRAY WHITE 10 BLACK 11 BROWN 12 RED 13 ORANGE 14 YELLOW 15 GREEN 16 BLUE 17 VIOLET 18 GRAY 19 WHITE 20 BLACK 1 2 3 4 5 6 7 8 9 z mz z Jal lols 9IS z a Dez S fas EIS FM S 8815155518555 51 lt 9 8555 85 5 al e A gt Jo BO gt 0 F B a 2 O ola Flo 2 m Lal Ea La CLD SPH QO coir sos ES Band LSI kaal LAI
104. SERVICE MANUAL PRESS RELATED PROBLEMS refer to troubleshooting guides for supplies for most press problems Short run length 1 Check press roller settings Recommended settings for most presses are Form to Plate stripe 1 8 3 mm Plate to Blanket stripe 3 16 5 mm 2 Verify that exposure is set correctly by checking Dax Laser power too high can cause short run lengths 3 Reduce laser power 72 CABLE 803314 001
105. Sets the amount of material in spool A up to 280 85 m 2 Spool B Sets the amount of material in spool B 3 Spool C Sets the amount of material in spool C 4 Spool D Sets the amount of material in spool D Status Menu Status ESC to exit 1 Sensor Status 2 Takeup Cassette Remaining 0000 3 Current Plate Count 000000 Total Plate Count 000000 Material Used 000000 ESC ENTER 1 Sensor Status This selection provides access to the Sensor Status menu 2 Take up Cassette Remaining Shows the amount of media capacity remaining in the take up cassette in feet The maximum allowable amount of material is 26 The Take up Cassette Remaining value is automatically decreased from 26 as media is used When this value reaches 0 the Platesetter will stop running 2 14 CONTROL PANEL 3 Current Plate Count This selection clears and displays the current plate count Total Plate Count Displays the total number of plates imaged by the Platesetter Material Displays the total number of feet of material run through the Platesetter Sensor Status Menu SENSOR STATUS ESC to exit LOAD KNOB WRKNG TANK LOW 0 FEED LOOP TANK LOW 1 EXIT LOOP EFFL TANK HIGH 1 IMAGER EXIT PROCTEMPLOW 0 NO MEDIA PROC EXIT 0 LOAD OK TAKEUP CASSETTE 0 GUIDE B ON ESC OFF ENTER The Sensor Status menu indicates the current digital status of all Platesetter sensors Expla
106. UT HEX UNC 8 WASHER CURVED SPRING 3 8 SCREW SHC 1 4 20 1 2 PLATE FI IDLER BEARING OIL LESS BRONZE DB119 COLLAR PULLEY SCREW SHC 6 32 X 50 E RING SAE 1 2 SHAFT KNOB PULL WASHER MOD ROD PIVOT BEARING NON METALLIC FLANGED BAR UNLOADING LINK PINCH UNLOADING SCREW SHC 4 40 X 50 KNOB KNURLED SHC 4 WASHER LOCK HELICAL SPRING 1 4 REG WASHER FLAT STEEL 1 4 REGULAR NUT LOCK K 6 32 E RING SAE 750 SHAFT E RING SAE 625 SHAFT SCREW SOCKET HD SHLD 8 32 X 2505 SCREW PAN PPH 4 40 X 63 NUT LOCK K 44 40 SCREW B H TORX 8 32 UNC X 375 WASHER EXTERNAL LOCK 8 RECEPTACLE 1 4 TURN RING EXTERNAL RETAINING NUT RECEPTACLE RETAINING FASTENER 1 4 TURN PUSH BUTTON SPRING COMPRESSION 75X 360X 038 SPRING COMPRESSION 2 00 X 660X 072 KNOB KNURLED SHC 8 SCREW FLAT HEAD 6 32 X 38 WASHER FLAT STEEL 8 NUT LOCK K 8 32 SCREW SHC 8 32 X 75 SCREW SHC 8 32 X 38 PRINTWARE Confidential 281 282 283 284 287 288 289 290 291 292 293 294 295 297 298 306 307 308 309 310 312 313 315 323 324 325 326 327 347 348 349 350 N oo NO WN UY N gt WW WR OND Assembly Number 808344 XXX 900963 002 900236 005 900224 005 900871 007 900235 002 900172 003 900236 001 900224 002 900319 001 900254 003 900276 006 900928 003 900235 040 900160 012 900235 041 900223 007 900222 003 900651 019 900445 009 900359 001 807093 003 807093 004 807093 006
107. VE BRACKET MOTOR MOUNT PULLEY MOD GROMMETS VIBRATION ISOLATOR SPACER ROUND 8 X 1 4 SCREW PAN PPH 6 32 X 1 WASHER FLAT STEEL 6 NUT SELF LOCKING HEX 6 32 WASHER FLAT STEEL 6 NARROW SCREW SHC 6 32 X 25 PRINTWARE Confidential 00 IF REQUIRED Printware ASS Y MOTOR MOUNT 803666 001 REVISION N Sheet I of I PRINTWARE Confidential Find Number 001 002 003 008 008 009 009 010 010 011 011 012 013 014 015 017 018 018 019 020 021 024 Quantity Component Used N A NOONE ee Neme Assembly Number 808152 001 ASSY CAPSTAN GUIDE Number 806320 001 806323 001 806324 001 806325 001 806411 001 806325 002 806411 002 806317 001 806412 001 806317 002 806412 002 900236 900871 001 900047 002 900236 008 806283 001 806517 001 806658 001 900277 026 900233 003 900871 007 900230 005 Revision B Component Description GUIDE STATIONARY CAPSTAN APERTURE CAPSTAN LINK CAPSTAN BRACKET CAPSTAN SHUTTER BRACKET CAPSTAN GUIDE BRACKET CAPSTAN SHUTTER BRACKET CAPSTAN GUIDE BRACKET CAPSTAN GUIDE BRACKET CAPSTAN SHUTTER BRACKET CAPSTAN GUIDE BRACKET CAPSTAN SHUTTER SCREW SOCKET HEAD SHOULDER 8 32 X 188 SCREW SHC LOW HEAD 6 32 X 38 WASHER EXTERNAL LOCK 6 SCREW SOCKET HD SHLD 8 32 X 2505 ASSY CAPSTAN LIGHT SEAL 18 SPRING CAPSTAN GUIDE SPRING HOOKED CAPSTAN GUIDE SPRING COMPRESSION 250 X 240X 020 NUT LOCK 8 32 SCREW SHC LOW HEAD 6 32 X 250 BEARING NYL
108. ace the belts install the new belts in reverse order 5 To replace the motor disconnect the cable from the motor Remove the motor from the bracket Install the new motor in reverse order Adjust the drive belt tension by adjusting the set screw on the motor shaft and or pulley shaft 21 SERVICE MANUAL 6 To replace the rollers remove the pulley from the shaft by loosening the two set screws Remove the E clips and spacers if any from each end of the lower shaft Remove the bushings from each end of the roller shaft Access the rollers from the top of the Platesetter Remove the upper roller by sliding the roller towards the rear of the Platesetter until it clears the frame Remove the lower roller by sliding the roller towards the front of the Platesetter until it clears the frame Install the new rollers in reverse order 7 Replace the back panel lower the marker assembly and close the top cover Removing the Pinch Rollers Left and Right See Figure S3 1 1 Open the top cover and raise the marker Remove the front and rear panel 2 Remove the traction control belt from the pinch and capstan rollers by pushing the belt tensioner to your right 3 Remove the E clips spacers if any and bushings from each end of the pinch roller shaft 4 Remove the spring loaded tensioner from each end of the roller shaft by removing the hex nut 5 Access the shutter from the top of the Platesetter Loosen the four screws on the sh
109. al Black Line 1 Brown Line White Line 2 Blue Neutral Green Ground Green Yellow Ground Verify that an electrician is available if needed 2 Confirm Supply of Recommended Consumables Have at least 16 gallons of working Activator on hand Have at least 16 gallons of working Stabilizer available Have plate media available as required Plate media may be either paper or polyester based Roll width may be from 9 to 18 1 22 9 cm to 46 0 cm The maximum roll length is 280 85 m INSTALLATION GUIDE RECOMMENDED CONSUMABLES FOR PLATESTREAM 46 PRINTWARE SILVERSTREAM RED LIGHT PLATE MEDIA Emulsion In 5 mil polyester 808555 XXX 280 FT ROLLS 8 mil polyester 808666 XXX 280 FT ROLLS CHEMISTRY ACTIVATOR 808777 001 STABILIZER 808777 002 AGFA SETPRINT PLUS RED LIGHT PLATE MEDIA Emulsion In 5 mil polyester SET R 0 13 8 mil polyester SET R 0 20 CHEMISTRY ACTIVATOR G5200 STABILIZER G5400 MITSUBISHI SILVER DIGIPLATE INFRA RED PLATE MEDIA Emulsion In Emulsion Out 5 mil paper SDP RD125 SPEC28 SPEC28R 7 mil paper SDP RD175 SPEC 28 SPEC28R 4 mil polyester SDP FD100 SPEC 820 SPEC820R 7 mil polyester SDP FD175 SPEC 820 SPEC820R CHEMISTRY ACTIVATOR SLM AC STABILIZER SLM ST RED LIGHT PLATE MEDIA Emulsion In Emulsion Out SDP RR125 SPEC28 SPEC28R SDP RR175 SPEC28 SPEC28R SDP FR100 SPEC820 SPEC820R SDP FR175 SPEC820 SPEC820R INSTALLATION GUIDE 3 Scheduling Installation Verify prep
110. al Effluent s Tank amp Cart Optional A xy 4 NS Replenishment Tanks Cart Optional Figure 3 1 Side View of the PlateStream 46 Note If the processor has not been in use for several days the racks can freeze up due to evapo ration causing rollers to stick together The racks should be removed and rinsed with water and rotate the gears to free them up Failure to do so can result in gear breakage 34 PREPARING FOR OPERATION Loading Plate Material 1 Open the platesetter top cover Raise the marker by pulling the marker lever towards the front of the platesetter until the lever stops Lift up the marker gently 2 Pull out the load knob on the left side of the platesetter From inside of the platesetter adjust the two rear edge guides by pulling the edge guide knobs up and sliding to the position closest to the plate media width 3 Adjust the two front edge guides by loosening the screw and moving all the way to the front 4 Open the feed cassette by lifting the back of the lid and sliding forward at the same time Remove the spool assembly Adjust the left hub to match the edge guide position by squeezeing the clip and sliding on the shaft Remove the right hub from the shaft by lifting the clip and sliding it off the shaft Slide the media onto the shaft Slide the right hub onto the shaft by lifting the clip and pushing down on the spool until the spool is tight against the media see Figure 3 2 Insert
111. alth CDRH of the U S Food and Drug Administration implemented regulations for laser products on August 2 1976 Compliance is mandatory for prod ucts marketed in the United States Always follow these basic safety rules when using the Printware Platesetter 1 Read this manual before using the Platesetter 2 Do not remove protective housings or external covers except as specified in this manual 3 Do not disassemble the Platesetter or try to repair it yourself other than as specified in the Preventive Maintenance and Troubleshooting sections of this manual Call an authorized service technician for necessary repair 4 Plug the power cord into a 3 conductor grounded earthed outlet only Never ground the cord to a gas pipe or a water pipe Keep the cord away from hot surfaces Avoid using an extension cord 5 Use caution when disconnecting any electrical connector within the Platesetter Do not disconnect electrical components with the Platesetter turned on 6 Be extremely careful when working on the Platesetter with the machine turned on and the top cover open Notice the warning label attached to the underside of the laser marker unit 7 Always read and follow all label instructions on supplies carefully Dispose of used supplies and containers appropriately 8 Use caution when working on or around rollers within the Platesetter with the power on Be especially careful when wearing loose fitting sleeves or a tie Follow simil
112. and Rack With Rollers Drive System SERVICE MANUAL CHAPTER 2 MAINTENANCE For physical calibration procedures see the PlateStream 46 Platesetter Installation Guide This chapter identifies which subassemblies within the Platesetter require lubrication details the procedures for lubricating the assemblies and shows the recommended frequency for performing each procedure This chapter also includes information on other preventive maintenance proce dures Performance of lubrication and preventive maintenance procedures is essential to keep the Plate setter in proper operating condition and to maintain optimal image quality Keeping the Platesetter and its surrounding area clean is also important Wipe excess oil from all parts after performing lubrication procedures Perform these procedures at the time intervals shown in the Platesetter Maintenance Schedule section to keep the Platesetter operating properly and avoid unnecessary repairs For detailed drawings and Printware replacement part numbers see the PlateStream 46 Platesetter Parts Manual Approved Lubricants The following lubricants are the only ones approved for use on the PlateStream Mobilith SHC 460 Silicone Stick Lubricant Cleaning Supplies Marker Mirrors Compressed air recommend type in Ultrajet E Series Precision Dust Remover Acetone 100 pure cotton non woven lintless non scratching fabric such as Webril Wipes Imager rollers N
113. ank amp Cart Optional Cart Optional Figure 1 3 Media Path of the PlateStream 46 Platesetter 1 4 GENERAL INFORMATION Features Overview Figure 1 4 illustrates the following features Panel High Speed Control Panel Power Switch Options The I O panel is located on the bottom rear of the Platesetter This panel is used to connect the Platesetter to an external RIP The Platesetter images plates at a rate up to 120 plates per hour and up to 36 inches per minute 91 cm min Plates emerge right reading for easy proofing and final plate checks The Platesetter can image any width from 9 to 18 1 22 9 to 46 cm Plates can be any length from 12 to 27 30 5 to 56 cm The maximum roll length is 275 84 M The control panel is an applet on the RIP The control panel keys allow you to perform a number of adjustment and diagnostic func tions and the 8 x 40 character liquid crystal display LCD screen displays status error messages and function menus The power switch is located in the rear of the Platesetter Film With this option the Platesetter can image film and load a take up cassette for off line processing Miniplate With this option the Platesetter will impose multiple jobs shorter than the minimum plate length Punch With the PunchStream integrated punch option the Platesetter will automatically punch the plate 2400 dpi the high resolution option allows imaging 2400 dpi esp
114. ap Assembly Number 808143 001 ASSY CHASSIS PLATESTREAM 46 Number 803314 001 804217 001 807226 002 803311 003 803312 002 806306 001 803318 001 803334 001 804149 001 803319 002 803321 001 901029 002 806376 001 806475 001 821521 001 900224 001 900813 001 600267 002 600320 001 900237 002 600307 001 803323 002 806366 001 900821 002 600272 000 600272 003 600272 004 900233 002 900445 004 901022 001 806275 001 806400 001 900445 006 806504 001 806461 001 806462 001 600188 003 900891 007 808153 001 900289 003 806614 001 806503 001 Revision B Component Description ASSY CABLE CON RIP ASSY CABLE BLK PROC ASSY CABLE INTERFACE TO SOLENOID ASSY CABLE CONTROLLER TO OPERATOR PANEL ASSY CABLE POWER OPERATOR PANEL ASSY CABLE MARKER FAN ASSY CABLE SCSI ENG ASSY CABLE BRK BLK ASSY CABLE FIL BRK ASSY CABLE POWER4 CON6 FAN A48 B43 ASSY CABLE ENG5 STANDOFF WIRE TWIST LOCK ASSY CABLE PROCESSOR I O GUARD CIRCUIT BREAKER ASSY CABLE GROUND STRAP 6 50 SCREW TAPTITE PPH 6 32 X 3 8 FILTER RFI K SERIES 30VK6 CIRCUIT BREAKER DOUBLE POLE 20A OUTLET 16 20A IEC 320 SCREW SOCKET FLAT HEAD UNC 4 40 X 3 8 OUTLET ACCESSORY PUSH IN ASSY CABLE ENG STEPPER ASSY CABLE CUTTER STEPPER POCKET PULL 4 84 X 1 84 040 070 TERMINAL BLOCK GREY 4 CONDUCTOR TERMINAL BLOCK GRN YLW 4 CONDUCTOR TERMINAL BLOCK END PLATE NUT LOCK K 4 40 SCREW B H TORX 6 32 UNC X 375 BEARING FLANGE ALIGN PLATE LOCATING LATCH SE
115. ar precautions when working on or around the cutter 1 7 GENERAL INFORMATION 9 Do not operate the Platesetter if any part of it is damaged or if any part has been dropped until you have it checked by an authorized service technician 10 When turning OFF the Power switch be sure to do it after the machine cycling has come to a complete stop 11 Use only supplies designated by Printware with your Platesetter Consult the recommended supplies list that came with your Platesetter system All supplies should be stored in a cool dry area The use of low grade or improperly stored media will result in print quality problems 12 There is a lithium battery in the battery backup RAM on the laser controller board U17 on 522980 XXX mounted to the top of the laser marker unit This lithium battery is not replaceable Dispose of or recycle all printed circuit boards properly WARNING Performing procedures adjustments or using controls in a way other than those specified in this manual can cause hazardous laser radiation exposure electrical hazards or damage to the Platesetter 1 8 CONTROL PANEL CHAPTER 2 The Control Panel The control panel is an applet that runs on the RIP The control panel program starts automati cally when the RIP is powered up Figure 2 1 illustrates a flowchart of the control panel menus The panel consists of an 8 x 40 character display which shows status messages and menu options and the fo
116. arations that the machine will arrive and can be moved to its final location loading dock clear hallways etc before scheduling installation The Platesetter should be installed by an authorized service technician 4 Verify Final Location Select a suitable place for installation Avoid excessive dust vibration and direct sunlight The Platesetter is designed for use in a prepress environment Acceptable ambient temperature range is 65 F to 80 F 18 C to 27 C and acceptable relative humidity is 45 to 70 Check the necessary dimensions at the physical installation site e g width of doors etc with the Plateset ter dimensions To ensure optimal operation allow clearances of at least 24 60 cm on the left 24 60 cm on the right 24 60 cm in front and 12 30 cm in the rear see Figure I 1 on page 9 After uncrating the depth of the Platesetter which is on casters is approximately 31 79 cm If the optional effluent tank is not ordered a method for plumbing to remove chemical effluence is required This method must meet local environmental codes The drain for the chemicals provided with the Plateset ter is a vinyl flexible hose 6 long 174 180 cm x 3 cm outer diameter and 1 inner diameter Precautions 1 Due to the 750 lb 340 kg weight of the Platesetter use caution when removing Platesetter from pallet 2 Follow electrostatic discharge ESD protective procedures when connecting cables or working near Pl
117. atesetter To adjust the SOT sensor scan width Figure 1 11 Adjusting Scan Width and Linearity 1 From the RIP output the Grid18 ps file 2 Measure the distance between points A and C see Figure I 13 If the distance between A and is gt 17 000 43 18 cm turn the sensor position screw counterclockwise If the distance between A and is lt 17 000 43 18 cm turn the SOT screw clockwise One full turn is approximately 0 030 0 08 cm To adjust the SOS sensor linearity Measure the distance between points A and B see Figure I 13 If the distance between A and is gt 8 500 21 59 cm turn the sensor position screw counterclockwise If the distance between A and B is lt 8 500 21 59 cm turn the SOS screw clockwise One full turn is approximately 0 015 0 04 cm Marker Position Adjustment Physical movement of the marker is not recommended There is however an operator panel adjustment to compensate for slight differences in marker location From the Main Menu on the control panel Press 4 More Information e Press 2 Calibrate Press 4 Marker Position xx xx The image can be moved up to 0 05 0 13 cm A positive value moves the image towards the non operator side a negative value moves it towards the operator side 1 20 INSTALLATION GUIDE Adjusting Image Len
118. atesetter PCAs including Ground yourself by touching the metal chassis of the Platesetter before connecting or disconnecting any cable Use a wrist strap and an antistatic work surface if possible when handling PCAs or other electronic components Always store and transport PCAs in antistatic bags INSTALLATION GUIDE Unpacking and Inspection 1 2 Keep all the shipping boxes braces crates and packing pieces in case the Platesetter needs to be repackaged Inspect the Imager and Processor crates for signs of shipping damage Report any damage discovered to the carrier immediately NOTE Procedures refer to wooden crates used for international shipments Procedures are similar for cardboard crates used for domestic shipments Unpacking the Imager 1 2 Remove the screws holding the top and sides of the crate labeled Imaging Module Remove the ramp from the foam cap and attach the ramp to the bottom of the crate using the two nails located in the front of the crate Remove the top cover sides and the foam cap Remove the plastic wrapping from the unit Remove the screws from the four wood blocks mounted to the bottom of the crate Remove blocks by slightly lifting the imager Roll the imager down the ramp and onto the floor carefully Unpacking the Processor 1 2 Remove the screws holding the top and sides of the crate labeled Processor Module Remove the top cover sides and the
119. ation become more critical the higher the screen Enhanced AM screens also called supercell screens These screening algorithms allow more precise screen frequencies and angles e g if the application calls for a 150 line 45 screen the separation will be reproduced more exactly with supercell screening Without supercell screening selected the separation screens might be approximated with a variety of different screens and angles causing moir Supercell screening also reduces moir and smooths transi tions in gray levels Enhanced AM screens are called Spectracell Screens on the ZAPrip 200 Level 1 RIP Accurate Screens on the Adobe PostScript ZAPrip and Harlequin Precision Screens HPS on the ZAPrip HQ Harlequin Xitron RIP C4 Plate tream 46 Platesetter Service Manual Printware LEADERS IN COMPUTER TO PLATE CONTENTS Chapter 1 General Information Ne 2 Construction of the Platesetter 4 Chapter 2 Maintenance Approved LUBriGarits 2 6 Cleaning Supplies 6 Platesetter Maintenance 7 Procedures to Raise and Lower the 8 Inspecting and Cleaning Marker Assembly Unit 9 Ma
120. ave Imager Setup to RIP Load Imager Setup to RIP ON ESC OFF ENTER 1 Calibrate Transport Provides access to the Calibrate Transport menu 2 Calibrate Marker Sets the marker to perform a full calibration the next time the machine is powered up 3 Input Spool Manager Provides access to the Spool Manager menu 4 Marker Position Adjusts the side to side image position up to 0 05 0 13 cm Increas ing the value moves the image away from the operator side decreasing the value moves the image towards the operator side to accommodate the physical position of the marker 5 Save Imager Setup to RIP Saves the imager setup data to the RIP hard drive 6 Load Imager Setup from RIP Reloads the Imager setup data into the Imager from the RIP hard drive 2 12 CONTROL PANEL Calibrate Transport Menu Calibrate Transport ESC to exit 1 Calibrate Processor Manual Length Adj Cut Length di Overlap Length Adj Backup Length Adj Punch Length Adj 500 Miniplate Backup Leng Adj 0 134 ON ESC OFF ENTER 1 Calibrate Processor Runs a plate which calibrates the processor exit sensor for the current resolution dpi setting Since Platesetter speed varies with resolution the processor exit sensor must be calibrated at the factory If the control panel error displays Media didn t exit imager or Media didn t exit processor calibrating the processor is one of the
121. ay Connect the keyboard cable to the keyboard connector on the back of the RIP CPU Attach the network cable to the network interface connector on the back of the RIP CPU Plug in the RIP electrical power cord s Connect the two interface cables between the RIP CPU and the Platesetter The Platesetter I O Panel is located on the bottom rear of the machine INSTALLATION GUIDE Turning On the Platesetter 1 The power switch for the Platesetter is located on the left side of the machine To turn on the Platesetter flip the switch up see Figure I 1 Each time the Platesetter power switch is turned on the Platesetter performs a series of tests of its internal components If an error message appears on the control panel see the section Responding to Control Panel Error Messages in the PlateStream 46 Operator Manual If the display stops at any initialization point for more than five minutes turn off the Platesetter and call for authorized service Platesetter boot up procedure takes approximately four minutes If best absolute accuracy is re quired allow six hours for the Platesetter to reach operating temperature Once the power up sequence is successfully completed the control panel screen will show the main menu with On Line mode indicated and no error messages displayed 12 30 cm rear clearance Right processor 24 60 cm left clearance Marker Lever Load Knob 47 19
122. ay a 1 indicates a low solution level in one or both of the tanks REPLN TANK LOW This sensor monitors the solution level in the replenishment tanks under neath the processor A 0 indicates the current level is okay a 1 indicates a low solution level in one or both or the tanks 38 SERVICE MANUAL EFL TANK HIGH This sensor monitors the level of spent solution in the optional effluent tank underneath the processor A 0 indicates the current level is okay a 1 indicates the tank needs to be emptied PROC TEMP OK The processor Activator Temperature sensor monitors the temperature of the Activator bath A 0 indicates that the current temperature is okay a 1 indicates that the bath is still warming up or that there is a problem with the heater PROC EXIT Indicates the presence or absence of media at the processor exit sensor A 1 indicates that media is present e g during imaging A 0 indicates the sensor is clear This is the normal operating condition EXIT CASSETTE Identifies the presence of an optional film takeup cassette A 1 indicates the film takeup cassette is present A 0 indicates that the film takeup cassette is not present 39 SERVICE MANUAL Replacing the Imager Sensors See Figure S4 2 1 Remove the front panel 2 Access sensors from the front of the Platesetter Disconnect the three pin connector from the sensor 3
123. between Miniplate jobs from the More Information Menu Press 2 to go to the Calibrate Menu Press 1 Calibrate Transport Press 7 Miniplate Backup Length Adj 5 To decrease the gap between jobs increase the value for Miniplate Backup Length Adj on the control panel To increase the gap decrease the value Note that Miniplate Backup creates a non imageable area equal to the Backup Length on the trailing edge of each job 6 If necessary follow the procedure for all resolutions to be used with the Miniplate mode Miniplate Backup Length is set independently for each resolution The default Miniplate Backup Length for each resolution is Default Miniplate Resolution Backup Length 900 dpi 0 134 1200 dpi 0 084 1800 dpi 0 021 2400 dpi 0 010 1 24 INSTALLATION GUIDE Punch Set up with optional punch installed The punch is an electronically actuated pneumatic system There is a compressed air connection on the lower rear panel of the platesetter Air should be clean and oil free and air pressure should be 80 Air can be supplied either from shop air or an optional auxiliary compressor The punch waste chip bin is attached magnetically to the wall in the back of the load compartment It should be removed and emptied periodically Punch Adjustment There are two physical calibration adjustments for the punch lateral side to side alignment and skew or parallelism to the cut edge Additionally
124. both ends Cycle the Platesetter power Reboot the RIP Media must be reloaded after jams or other fault conditions to prevent a reoccurrence of the jam 2 3 Reload Media message should clear after reloading If message does not clear check for defective sensor PROBLEM No Plate Exits from Platesetter Plates Jam Skewed Wrinkled or Torn Plates IN CASE OF TROUBLE SOLUTION 1 Ensure that the Platesetter is not out of plate media 2 Ensure that the plate media is properly loaded and aligned 3 Open the covers and check media path See chapter 7 Clearing Media Path 4 Inspect and clean the feed rollers See chapter 7 Clearing Media Path 1 Ensure that plate media is properly loaded 2 Clean the rollers see Chapter 6 3 Replace the plate material 7 8 IN CASE OF TROUBLE PROBLEM SOLUTION White Black or Silver 1 Clean processor and replace chemistry Streaks on the Plates Brown Haze on Plates 1 Clean processor and replace chemistry 2 Clean the processor rollers Wet Plates 1 Clean the dryer 2 Clean the processor and replace the chemistry 7 9 IN CASE OF TROUBLE Clearing Media Path 1 Pull the load knob and gently lift up the top cover and MARKER see Fig 7 1 2 Inspect the MEDIA PATH for jammed media in the areas described below Access the MEDIA PATH through the top and front covers of the Platesetter GUIDE A CAPSTAN GU GU GU
125. c control kit if not already in place sionally when loading media 2 Check for faulty power supply S 2 1 From the Operator Panel turn on all motors and y cycle the cutter several times If the Operator Panel blanks out the power supply is being overloaded You can increase the voltage by removing the power supply and turn the 5V potentiometer 2 hours 60 clockwise 2 2 If adjusting the 5V does not solve the problem replace the power supply assembly Operator Panel locks up 1 Install static control kit if not already in place 2 Replace the Operator Panel assembly 49 SERVICE MANUAL MARKER GALVANOMETER PROBLEMS For all galvanometer errors recycle the platesetter to clear spurious errors If errors persist use the following steps before replacing the marker assembly Galvo initialization stops at 00 02 03 05 07 10 gt Check cables between controller PCA and marker assembly Check controller PCA and power supply voltages Check voltages at power supply Check fuses and replace if necessary Replace Power Supply if necessary Calibrate the marker Replace the controller PCA Replace marker assembly Check galvo connector J14 on the controller PCA 2 Check voltage across R267 or R266 on the gn controller PCA Calibrate marker Replace controller PCA Check galvo connector J14 on the co
126. ce 15 14 990 enter 010 The length change displayed is reset to 0 after pressing enter Print the Grid ps file again and measure the distance between points and 4 Repeat steps 1 through 3 until length is within specification 5 At 900 dpi the manual length is adjustable in 0 006 0 015 cm increments at 1200 dpi in 0 004 0 01 cm increments 1800 dpi in 0 003 0 08 cm increments and at 2400 dpi in 0 002 0 005 cm increments NOTES It is best to make small incremental changes Once you enter a new value for Manual Length Adj it is immediately copied to the battery backup Be careful not to make big adjustments as this could result in corrupt data in the firmware specification for image length accuracy is 0 003 75 microns 1 21 INSTALLATION GUIDE Overlap Adjustment In waste reduction mode the Platesetter scans the leading and trailing edges of the plate causing a black area to appear This black area is the unimageable area of the plate At the leading edge of each plate is a double exposed area visible as a black band where the media was exposed on the trailing edge of the previous plate backed up and re exposed on the leading edge of the current plate If a silver line appears in this lead area then the overlap adjust is set too low 1 From the RIP JOBS directory on the RIP output the Grid 18 ps file 2 To make the adjustments described below from the Main Menu on t
127. ck e Replace the front and rear panels 6 Plastic wrap the entire Imager Place the foam cap over the Imager Place the ramp inside the foam cap Place the 33 84 cm wide plywood with notches on the front of the crate with the boards facing inside the crate and the notches on the bottom Place the 33 84 cm wide plywood on the back of the crate with the boards facing inside the crate Place the two 50 127 cm wide plywood on the sides of the crate with the boards facing inside the crate and flush with the bottom Screw the top and the sides together Make sure the top cover and the sides are very secure D Package the Accessories 1 Place the accessory box marker box and RIP boxes on the crate 2 Place sides and top on the crate Screw the top and sides together Make sure the top and sides are secure 1 31 INSTALLATION GUIDE This page should be filled out on Installation Serial Numbers and Factory Settings Installation Date Location Serial Numbers Component Serial Model Imager Unit Laser Marker Assy RIP CPU RIP Monitor Setup punch and 2400 dpi values are applicable only if those options are installed Resolution 900 1200 1800 2400 Cut Length Overlap Length Backup Length Punch off Backup Length Punch on Punch Length Punch on Miniplate Backup Length Image Power Processor amp Mini Plate Image Power Cassette MT Speed 1 32 Plate tream 46 Platesett
128. cm piece of tape on the bottom of the laser marker over the slot for the laser light c Detach the right cover strut on the marker end by removing the cap and pulling the strut off the ball joint d Detach the strut on the laser end while holding the marker in the upright position by removing the cap and pulling strut off the ball joint e Fasten the shipping brace to the laser right end of the marker with eight screws NOTE If the marker is being repackaged without separating the Imager and Processor modules the marker must be removed before installing the shipping brace f Detach the strut from the galvo left end of the marker g Reattach cap to struts 3 Remove the marker a Place blue plastic bag and two DESI PAK bags in the marker assembly carton with the bag laid open b Using two people remove the marker from the Platesetter c Slide the marker assembly off the brass pivot bushing located furthest from the processor section left without moving the bushing d Slide the marker assembly off the brass pivot bushing located on the right without moving the bushing 4 Place the marker in the carton a Place the marker assembly in the blue plastic bag with the laser end placed in the location shown on the drawing that is attached to the bottom of the carton b Fold the blue plastic bag around marker and tie wrap shut c Install foam block in the location shown on the drawing in the marker box d Place f
129. d for critical work B 3 CALIBRATION II Calibrating the ZAPrip HQ Harlequin RIP The goal of calibrating the RIP is to linearize the transfer curve Figure la shows a calibrated transfer curve and Figure 1b shows a non linear uncalibrated transfer curve Linear Output Non Linear Output 100 100 50 amp 50 7 0 0 0 50 100 0 50 100 REQUESTED REQUESTED Figure la Figure 1b The Z4Prip HO Harlequin RIP Print Calibration menu allows you to print test strips calibra tion targets Calibration Manager allows you to create and edit calibration sets and to enable or disable particular sets Xitron RIP xiton Edit Preview Color Output Fonts GUAM ENS Calibration Dot Gain Manager displays calibration sets grouped by device When you select from the Device drop down list all ofthe existing calibration sets for that device are displayed The basic calibration steps are as follows see the RIP manual for detailed procedures 1 Select Print Calibration to print an uncalibrated target see Figure 2 B 4 CALIBRATION Uncallbratod Target tor device PlateStream uscetitrates ge B C m a m aY Fei May 35 1960 120522 Figure 2 Calibration Target 2 Measure the density of each square ofthe target with the densitometer Note that the densities marked on the target are reversed e g the 10 square will be marked 9
130. d with pliers until blade is of the way through the silver plate on the inside Tighten set screws on arm and test the cutter before reinstalling cutter in machine PUNCH PROBLEMS Punch does not operate or does not punch all the way through SERVICE MANUAL 1 At the Operator Panel verify that the punch option is turned on 2 At the regulator on the compressor check the air pressure should be approx 80 psi 2 1 If no air pressure Check that the compressor is plugged in and turned on If you can hear the compressor try adjusting the regulator control on the air compressor Check for leaks around air hosefittings on the punch the punch solenoid and the air compres Sor If air pressure is still inadequate replace the compressor 2 2 If air pressure is adequate Check the cable from the punch solenoid to the interface PCA and re seat the cable Check that the air compressor gauge is not stuck Purge the air by opening the valve on the bottom of the glass regulator tube Then let it come back up to 80 psi Turn off the platesetter plug the punch solenoid wire into the shutter connector on the interface PCA Turn the Platesetter power back on and then at the Operator Panel run the shutter to see if the punch operates If so replace the interface PCA If the punch doesn t work when plugged into the shutter connector on the interface PCA replace the punch solenoid cable as
131. dia is imaged see Spool Manager later in this chapter Each spool can hold up to 280 85 m each spool s counter can be reset after reloading Input spool selection will be displayed in front of the feet remaining in the main menu 6 Destination Sets the output destination for the imaged media Choices are Processor Processor Miniplate with the Miniplate option and Cassette with the film option For a standard PlateStream 46 with no options installed Processor is the only destination 7 Display Units Toggles between English and Metric display units NOTE This manual generally refers to English display units with Metric units in parentheses where applicable CONTROL PANEL Test Plate Menu Test Plate ESC to exit 1 Run 01 Plates 2 Choose Pattern Composite Pattern 3 Choose Length 13 On Line Transporting A0075 1800 DPI PROC ON ESC OFF ENTER 1 Run Plates Sets the number of plates from 1 to 99 Pressing ENTER sets the specified number of plates to be printed Pressing ENTER again causes the specified number of plates to be printed As each plate is printed the displayed number will decrement by 1 Printing can be interrupted by pressing the ESC key If printing is interrupted the current plate will be imaged the Platesetter will not print the remaining plates the displayed number will return to its selected value If printing is not interrupted then once the spec
132. e RIP is running The spool directory is set in the RIP setup under the Configure Edit Setups Spooling menu item f Reboot the RIP Adobe PostScript ZAPrip a Loginas Administrator with password printware b Double click on the ZAPrip icon to launch the RIP c Hit F6 to start the RIP output queue PREPARING FOR OPERATION ZAPripHQ Harlequin Xitron RIP a b 4 Press ctrl alt del to log on Log in as Administrator with password printware Double click on the ZAPrip icon to start the RIP Choose Start Inputs from the Xitron RIP menu to start the RIP 2 Print a Job a b e Be sure your front end computer can see the network hot folder The Adobe and ZAPrip HQ Harlequin RIPs can use the Mac chooser as well as a hot folder To set this up use the chooser to select the desired PlateStream output device and resolution If a print driver is required use Adobe 4 2 for WIN95 Adobe 5 for NT Create a test job whose document size 1 equal to the desired plate size Print the job saving it as a PostScript file in the spool hot folder or using the print command if using set up with Mac chooser PREPARING FOR OPERATION Miniplate Option With the Miniplate option the Platesetter accommodates jobs shorter than the 12 minimum plate length by imposing several small jobs down the length of a plate To turn Miniplate on change the destination to Processor Miniplate in the Setup Me
133. e imaged media The choices are Processor Processor Miniplate with Miniplate option or Cassette with film option 7 Display Units Toggles between English and Metric display units QS 3 QUICK START GUIDE ZAPrip HQ Harlequin RIP Setup Imaging Plates 1 Startup the RIP a Connect the RIP to the network and turn it on b Press ctrl alt del on the RIP to log into Windows NT c Log in as Administrator with password printware d Double click on the Navigator icon to launch the RIP Create appropriate page setup s in Page Setup Manager a Ensure that the Negative box is unchecked b Specify plate size and image positioning in the page layout menu c You can specify screens in the Screening menu or leave it at factory defaults Over ride frequency and spot function Euclidean Spot Function 100 to 150 frequency depending on resolution the default Angles Use Harlequin Precision Screening and Rotate screens according to Page Rotation Publish the Page Setup on the network in Input Controller The name associated with the Page Setup in Input Controller will show up on the front end computer Note You may want to specify a name which incorporates resolution plate size or the target press e g GTO2up2400dp1 Choose Start Inputs the green traffic light icon from the RIP menu Set up the front end computer to print to the RIP For best results use the Adobe print driver and
134. e light is on set temperature by adjusting potentiometer R43 Clockwise turns heat up on most PCAs instructions are on the inside of the processor panel 3 3 If Heater Up To Temperature light is always on regardless of the R43 setting replace the thermistor Check heater element 4 1 Remove dryer heater assembly from processor 4 2 Check heater element resistance with an ohmmeter Normal values are Pin to Pin 2 45Q Pin to Pin 3 45Q Pin 2 to Pin 3 88Q Pin to Pin 4 Open 68 SERVICE MANUAL PROCESSOR ELECTRICAL PROBLEMS cont Replenishment pumps not turning Pumps turning but fluid output is inadequate Activator bath is too hot 69 Check the effluent tank If it is full the pumps will not come on If the replenishment tanks are low the pump will not come on Check the Check Pump prime light on processor PCA If the light does not come on when the pumps should be on replace the processor PCA Measure the voltage across the pumps at TS2 2 brown and TS2 3 blue If220V is present replace pump assembly If220V isn t present the replace the processor PCA Verify that there is chemistry in the replen ishment tanks Check for leaking hoses Check for air in the hoses If there is unplug the hose from tank and hold the end over the tank as it pumps until the air is cleared Check for pinched hoses Adjust pump rate see Installation Guide chapter 1 for adjustment
135. e plate material 13 Image one test plate from the control panel Test Plate menu Note Destination must be set to Processor see section Control Panel Set up menu 05 2 QUICK START GUIDE EMULSION OUT MEDIA EMULSION IN MEDIA Right Hub Right Hub Left Hub Position 18 Figure 05 1 Loading Plate Media on Spool Control Panel Setup Menu The control panel Setup Menu below lists six options for changing various Platesetter parameters Setup ESC to exit 1 Image Negative Right 2 Resolution P 1800 3 Image Power 4 Media Width 13 12 poo Pos 13 5 Input Spool Destination er Display Units English ON ESC OFF ENTER 1 Image Sets the type of imaging The choices are Positive or Negative Wrong Reading and Positive or Negative Right Reading The default is Negative Right reading for plate media 2 Resolution Sets the resolution The choices are 900 1200 1800 or 2400 dpi 3 Image Power Sets the image power laser intensity 4 Media Width xx xx Spool Pos yy Media Width is the exact width entered by the operator from 9 00 to 18 10 22 90 cm to 46 00 cm Spool Pos indicates the position to set the spool or cassette Spool position is set at the media width in inches rounded to the nearest inch from 9 to 18 5 Input Spool Specifies the input spool The choices are A B C or D 6 Destination Sets output destination for th
136. ecessary Deglaze the rollers Check the paper supply and clean the blanket Replace with correct concen tration Allow the blanket to dry be fore roll up Deglaze the blanket PROBLEM Slow Roll up or Poor Ink Transfer Weak or Uneven Image lose fine lines pinholes in solids Fuzzy or Blurry Image Marks on Plate or Scratched Plates N U gt CAUSE 1 The press fountain concentra tion or ink is incorrect The press ink fountain balance is incorrect The press rollers or blanket is glazed Press pressure is insufficient Exposure laser intensity is set too high Platesetter processor chemistry is dirty N Laser is out of focus The Platesetter rollers are dirty N Bad plate material Platesetter processor chemistry is dirty IN CASE OF TROUBLE SOLUTION 1 Check and replace if necessary 2 Check the balance and correct if neces sary 3 Deglaze the rollers or blanket 4 Check the pressure and adjust if neces sary 1 Adjust the exposure in the Platesetter Setup menu on the control panel per plate Media Manufacturer s instruc tions 1 Clean processor and replace processor chemistry 2 Call for service 1 Clean the Platesetter rollers 2 Replace the plate material 3 Replace processor chemistry 7 4 IN CASE OF TROUBLE PROBLEM Plugged Images or Excessive Back ground Wr
137. ecially useful for imaging film Infrared With this option the Platesetter will image Infrared 780 nm plate material Effluent Tank This option eliminates the need for direct plumbing of chemical effluence GENERAL INFORMATION 12 30 cm Right processor rear clearance lt S 24 60 cm left clearance gt Marker Lever Load Knob 47 119 Power Switch X SM P I 24 60 cm Rear I O panel right clearance Supply Cassette I 52 132 24 60 cm front clearance Figure 1 4 Features of PlateStream 46 Platesetter 1 6 GENERAL INFORMATION Operator Safety The Printware Platesetter has been certified as a Class 1 laser product under the U S Department of Health and Human Services DHHS Radiation Performance Standard This standard is in accordance with the Radiation Control for Health and Safety Act of 1968 A Class 1 certification means the Platesetter does not produce hazardous laser radiation The laser light produced inside the Platesetter is completely confined within protective housings and external covers The laser beam cannot escape from the Platesetter during any phase of user operation provided the user follows the operating instructions specified in this manual A warning label is attached to the bottom of the laser marker unit This label is visible whenever the media path hood is open The Center of Devices and Radiological He
138. eck for air leaks 61 PROCESSOR JAMS Plates jamming at processor entrance SERVICE MANUAL Check that the processor tanks are fully seated Check that the infeed rollers on the activator rack are turning Check that Guide D is properly installed Check that the imager exit switch engages to turn the processor on Adjust the imager exit switch arm COVER E 7 WIRE GUIDES 4 PLACES Correct processor guide placement Media is being bent in processor Verify the wire guides are installed properly they are easy to put in backwards Verify that the media is coming out of imager module straight Check to see if media comes out of the activator rack straight under the crossover guide Adjust activator stop bracket 62 SERVICE MANUAL Short plates jamming in the activator rack One plate comes out of processor and then the messages media did not exit processor and load media both come up 63 Verify that plate length is within platesetter limita tions 8 5 or 21 cm minimum for PlateStream MicroPlate 12 or 30 cm minimum for all other models Check that the processor wire guides are correctly installed see diagram above for correct proces sor guide placement Verify that the rollers in the activator and stabilizer racks are turning Check processor exit switch in Sensor Status menu Calibrate the processor from Operator Panel SERVICE MANUAL PROCESSING
139. edia was not detected by the Imager Exit sensor within the expected amount of time SOLUTION 1 Clear media path See chapter 7 in the section Clearing Media Path 2 Calibrate the processor See chapter 2 in the section Calibrate Menu CAUSE The sensor under cover G is blocked SOLUTION Clear media path See chapter 7 in section Clearing Media Path CAUSE The leading edge of the me dia was not detected by the processor exit sensor within the expected amount of time SOLUTION 1 Clear media path See chapter 7 in section Clearing Media Path Media didn t exit processor 2 Calibrate the processor See chap ter 2 in the section Calibrate Menu 45 requesting to image plate Scan initialization time out OPERATING THE PLATESETTER CAUSE The Platesetter electronics have detected a problem with one of the power supply voltage levels SOLUTION Turn off the Imager and call for service CAUSE A print job was sent to the Platesetter while it was not in the On Line state SOLUTION From the Main Menu on the control panel press 3 to return the Platesetter to the On Line state Cause The marker unit did not power up cor rectly within the expected time SOLUTION 1 Turn the Platesetter off wait 30 seconds turn the Platesetter back on and wait for the power up to be completed 2 Call for service 46 OPERATING THE PLATESETTER CAUSE The ma
140. elt and gears are rotating properly From the operator panel reset processor press 7 Switch off the Platesetter power 10 Replace the panels and wire tray Close the top right cover I 14 INSTALLATION GUIDE Calibrate the processor from operator panel This calibration checks to see how long it takes the leading edge of a plate to get to the exit switch of the processor This allows the Platesetter to properly detect a jam condition This calibration should be run at each resolution 900 1200 1800 and 2400 1 Load the plate material 2 From the operator panel calibrate the processor press 4 2 1 1 enter A plate will run through the processor 3 From the operator panel press esc esc esc to return to the main menu xc Stabilizer Rack Activator Rack 5 PA Dryer Belts E E ON Dryer Drive Clutch ANA NS Rack Drive Gear Dryer Drive Belt Drive Motor Belt Drive Shaft Worm Gear Figure I 3 Inside view of the Processor module Heater Element PROC EAR Switch i Drive R42 RAS 2 Motor MK KOG Processor PCA N A No p VA A PCA Screws Blower Figure I 4 Right side view of the PlateStream 46 Platesetter I 15 INSTALLATION GUIDE Physical Calibration Overview Follow the procedures detailed in this section to calibrate Platesetter for production at the customer
141. embly Replenishing Replenishment occurs when the media is depressing the switch in the dryer The media travels at 37 inches minute 94 cm minute and the pump can be adjusted to replenish a certain amount for each plate There is a 10 turn adjustment screw on each pump turn clockwise to increase the flow rate Sensors are in the replenishment tank see figure 52 2 14 SERVICE MANUAL NOTE If the effluent tank accessory is being used and the tank is full the replenisher pumps will not run Controls Prime Pump On the control panel Run Hardware Menu Used to activate the pumps They will run for 5 minutes and then stop Reset Used to clear all systems and prepare the processor section for a new job Quarterly Maintenance To run the processor with the top cover open use the Printware switch part number 807256 001 Insert flat edge of switch with finger locking into the hole on the side of the interlock bracket The black interlock bracket is located in the rear of the Platesetter above the processor dryer See Figure 52 2 1 Open the top cover See Figure 52 3 and 52 4 Inspect all gears and bearings for wear 2 Make sure that the dryer drive belt is tight If the dryer belt is jumping loose or is sagging it can be tightened by adjusting the bracket on the side rail Loosen the two screws in the bracket and move towards the solution racks to snug up the drive belt Tighten the two screws 3 Make sure that the d
142. emistry see Operator Manual 4 2 Inspect marker mirrors and clean if necessary see Chapter 2 S23 Adjust laser focus see Chapter 2 White black or silver streaks 1 Set Density Dot calibration see Installation Guide 2 Increase exposure control panel setup menu Inspect marker mirrors and clean if necessary see Chapter 2 Dirty silver colored spots Clean infeed and pinch rollers with D Ink 46 SERVICE MANUAL REGISTRATION AND SKEWING Image length incorrect too long or too short Image width incorrect too wide or too narrow First plate after a load misregistered on process color jobs 47 S22 Run a Printware Grid18 from the RIP Check to be sure scaling in RIP is set at 100 Then mea sure If source of problem is platesetter errors of less than 250 3 mm can be corrected with the Opera tor Panel length adjustment procedure see Opera tor Guide Run a Printware Grid18 from the RIP Check to be sure scaling in RIP is set at 100 Then mea sure If the source of problem is indeed platesetter errors of less than 1 8 3 mm can be corrected by realigning the SOS and SOT sensors Check loading and guide positions Consider sending blank or test plates before color jobs to eliminate first plate skew REGISTRATION AND SKEWING cont SERVICE MANUAL Tracking or skewing problems 1 Adjust roller spring tensions X Tools required tension gauge p
143. eplenishment probes for continuity If cable checks out OK replace the PCA Otherwise replace the cable Check probe connector Check cable P3 and PCA see procedures under Spurious low replenishment message Remove the right side end panel Push the exit switch actuator at a 45 angle An indicator light should turn on after a 6 second time delay from the switch clicking on If there is not an audible click when the switch is actuated readjust the switch If it cannot be readjusted replace the switch Ifthe switch actuates but the light doesn t come on replace the switch and cable Ifa new switch and cable does not resolve the problem replace the PCA SERVICE MANUAL PROCESSOR ELECTRICAL PROBLEMS Processor keeps running after media exits Dryer not heating Ensure imager exit switch works by manually feeding media over the switch and watching to see that it toggles between 1 and 0 in the Sensor Status menu If the switch works lower the upper media guide Guide C to force media to feed closer to the switch or reform or adjust switch upward Check and re seat connectors J4 and J12 on the Processor PCA Check fuses F3 and F4 on the processor PCA Check the Processor PCA 3 1 Check that dryer heater LEDs A and B are on when the heater should be on i e processor on and Heater Up To Temperature light not on If LEDs do not go on replace the processor PCA 3 2 If Heater Up To Temperatur
144. er Operator Manual Printware LEADERS IN COMPUTER TO PLATE 700580 Rev E COPYRIGHT NOTICE This manual is copyrighted and all rights are reserved Under copyright law this manual may not be copied by any means or in any form in whole or in part without the written consent of Printware Printware Inc makes no representations or warranties with respect to the contents hereof and specifically disclaims any implied warranties of merchantability or fitness for any particular purpose In addition Printware reserves the right to revise this publication and to make changes from time to time in the content hereof without obligation of Printware to notify any person of such revisions or changes 1997 by Printware Inc IBM and PC are registered trademarks of International Business Machines Corporation ZipRip ZAPrip and Printstyle are trademarks of Printware Inc Macintosh and AppleTalk are registered trademarks of Apple Computer Inc PostScript is a registered trademark of Adobe Systems Incorporated Futura is a registered trademark of the Fundicion Typografica Neufville SA Times is a registered trademark of the Linotype Company Printstyle is licensed to make use of the PostScript page description language copyrighted by Adobe Systems Inc PRINTWARE INC 1270 Eagan Industrial Road St Paul MN 55121 Phone 651 456 1400 Part Number 700580 Rev E May 9 2000 The camera ready master for this manual was gene
145. er until lever is horizontal Reattach the right cover strut by firmly pushing the strut head onto the ball joints and reattaching the caps to lock the strut INSTALLATION GUIDE 14 Remove bubble pack from cables Connect the cables to the marker assembly as follows 15 16 17 18 Connect the orange and white wires to the connector located towards the front of the Marker next to the fan Connect the grounding strap from the rear of the marker assembly to the Imager unit frame Connect the 10 wire connector to connector J6 on the printed circuit card PCA assembly located on top of the marker assembly Connect the connector with a single ribbon cable to the connector J8 on the PCA Connect the connector with three ribbon cables to J9 on the PCA Remove the Imager front and rear panels Remove the bubble pack from the black power cord located on the left side of the Processor Feed the black power cord through the large hole located on the right side of the Imager Plug the black power cord into the side of the power supply located in the bottom rear of the Imager Remove the bubble pack from the ribbon cable located underneath the processor Connect the ribbon cable into the connector located in the right side of the Imager Check the level of the Processor and the Imager If the Processor or Imager is not level use the casters to raise or lower the Processor or Imager If the top covers touch when the covers are
146. ers and clutches pumps blowers motors O rings heater tem peratures marker focus calibration etc SERVICE MANUAL Procedures to Raise and Lower the Marker Open the top cover and raise the marker by pulling marker lever towards the front of the Platesetter until lever stops Lift up marker gently Lower marker by gently lowering the marker and lock by pushing marker lever towards the rear of the Platesetter until lever is horizontal See Figure S2 1 Laser Beam mate Assembly a _ Focus Screw Spherical _ 00 Reversin Mirror Mirror ES Aperture gt Folding re Cover Lower Cover GO Mirror Screws Galvanometer Screws pe Figure S2 1 Side View of PlateStream 46 Marker amp Imager SERVICE MANUAL Inspecting and Cleaning Marker Assembly Unit Mirrors CAUTION Marker Assembly mirrors should be inspected and cleaned only if absolutely necessary The marker unit mirrors have a sensitive surface coating and are easily scratched Once a mirror is scratched it is ruined and the entire Marker assembly unit must be returned to Printware for mirror replacement and realignment Overview Under certain conditions it may be necessary to inspect and clean the Marker assembly mirrors Carefully check the condition of the marker Clean only when necessary Normally only the folding mirror the mirror visible through the aperture requires cleaning The laser beam is f
147. es On Line Ready Trans Imager ready to start imaging plate still in imager On Line Ready Proc Imager ready to start imaging plate s in processor only On Line Feeding Moving media into or through imager A0075 Approximate number of feet of media left on input spool A if length of media on the spool was entered when the spool was loaded 1800 dpi Current resolution Line 7 NO MEDIA No media detected at sensor closest to input spool LOW WORKING Either or both of the processor working tanks are low TAKEUP FULL The takeup cassette counter has counted down to 0 starts at 26 or 8 m when media is loaded may also be manually set INTERLOCK OPEN The marker is in the raised position Line 8 LOW PROC TEMP The processor is not up to specified temperature yet HIGH EFF The effluent tank is full LOW REPL Either or both of the replenisher tanks are empty CONTROL L PROC Imager destination lower right corner of operator panel PROC MINI MINI3 CAS CAS00 CAS21 Setup Menu Imager is in processor mode Imager is in miniplate mode there are No accumulated miniplates in the imager Imager is in miniplate mode there are 3 accumulated miniplates in the imager if there are more than 9 accumulated miniplates the digit changes to a Imager is in cassette mode and the media has not yet been loaded Imager is in cassette mode the media has bee
148. ess is incorrect 1 2 IN CASE OF TROUBLE SOLUTION Handle plate media more carefully Change the fountain solution and the ink Change the fountain solution Use only distilled water for preparing solution Clean the rollers Change processor chemistry Change plate media Clean up press and reduce ink Replace the fountain solution Be sure to use distilled or deionized water for preparing the solution Check the stripes pressure be tween the press rollers 7 6 IN CASE OF TROUBLE General Troubleshooting PROBLEM The Platesetter will not Turn ON No Power Platesetter will not Start a Print Job Reload Media or Manually Reload Media message Platesetter will not Start a Print Job 7 7 1 2 1 SOLUTION Ensure that the Platesetter is plugged in Check the fuse or breaker for the outlet Try unplugging the Platesetter and plugging another electrical item into the outlet to be sure that it has power The Platesetter may not have completed its power up sequence When the Platesetter is ready the Main Menu will be dis played on the control panel with On Line indicated and no error messages Ifan error is reported on the control panel correct the problem following the procedure in Chapter 4 then press ESC and 43 Ensure that the interface cable between the and the Pla tesetter is securely connected at
149. etter lift guide from the front of the Platesetter and remove d Remove Activator and Stabilizer racks Clean processor working tanks using warm soapy water Drain and clean the hoses 4 Package inside of processor a Place 4 plated metal or plastic Styrofoam pieces in the front operator side of processor working tanks Place 2 non plated Styrofoam pieces in the rear non operator side of the working tanks Replace the activator and stabilizer racks and tape them down Replace Guide D Bubble wrap cover E guide F and overflow tubes and tape to the top of the working tanks Place bubble wrap over Cover G and tape down 5 Package Carts a b Roll out the replenishment cart and the optional effluent cart Remove probes from the replenishment tanks and the optional effluent tank air blow dry and place them in the plastic clip located underneath the right side of the processor section Empty tanks per local environmental codes Individually bubble wrap the cart s and tanks Place cart s in the accessory box Remove 6 long 144 180 cm x 3 cm diameter vinyl hose from underneath the processor Place in accessory box 1 28 INSTALLATION GUIDE 6 Disassemble the Processor Remove the left front and rear panels Disconnect the ribbon cable from the connector located in the left side of the Processor Bubble wrap the end of the ribbon cable
150. for technical reasons that do not affect the principles of halftoning Within each color separation the size of the dots in relation to their background is proportional to the amount of the primary color in the compos ite shade When the separations are combined typically by overprinting in registration they create the illusion of shades of color The cyan magenta and yellow dots cannot be distinguished when viewed from a distance instead the pattern of color dots appears to be an area of a shade of color Halftoning can be specified in the front end application or can be overridden and specified in the RIP The three halftone parameters to be specified are 1 The shape of the dots created 2 The frequency and angle of the dot pattern 3 The screening algorithm 1 conventional AM or enhanced supercell screening HALFTONING AND SCREENING Dots Halftone Cells and Screens Dots are the visible part of halftoning and most halftoning can be described in terms of patterns of these dots The industry standard terms used to describe the organization of these dots into manage able structures are halftone cells and screens Each dot is considered to occupy a halftone cell Figure ApB 1 shows two groups of four halftone cells Every halftone cell is used to represent a gray level or color intensity A dot can have any area in the range 0 of the area of the halftone cell a completely white cell through 100 of the area of the
151. fore reloading to ensure a reliable load Remove leader from daylight load media before loading media Media must be loaded with no tears or wrinkles Media must be reloaded after jams or other fault conditions In this case a message will appear on the operator panel to Reload Media or Manually Reload Media EMULSION OUT MEDIA EMULSION IN MEDIA Right Hub Position 18 Figure 3 2 Loading Plate Media on Spool PREPARING FOR OPERATION Imaging Plates 1 Configure RIP Connect to the Network ZAPrip 200 Level 1 ZAPrip a Exit RIP and watch for the reboot warning RIP will reboot in 15 seconds b Hit ctrl c when you see the message c Answer Y to Terminate batch job d Set up network connection For AppleShare networks At the DOS prompt enter CD PHONENET Enter DA to start Phonenet desk accessory Use DA to log on to your AppleShare file server and mount a folder directory The directory will be mounted on the RIP as the I drive Exit DA For Novell networks At the DOS prompt enter CD NWCLIENT Enter NET to start Novell network utility Log on to your Novell file server an mount a volume directory The directory will be mounted on the RIP as the I drive Exit NET e Change directory to I and enter MD RIP to create the hot folder This is the folder the RIP will monitor for incoming PostScript jobs Postscript files placed here will be processed automatically when th
152. gth This procedure enables you to fine tune the image length setting of the Platesetter to Leading Edge compensate for small mechanical variations in components such as the rollers or drive motors This adjustment is made on the Calibrate Transport Menu on the con trol panel This procedure should be com pleted for 900 1200 1800 and 2400 dpi NOTE Before adjusting image length clean all transport rollers inside the Plate setter 1 From the RIP JOBS directory on the RIP output the Grid18 ps file Operator Side front of Platesetter 2 Measure the distance between points A and see Figure I 14 Use a preci sion steel ruler or digital measuring de vice to check this distance a digital mea suring device is more precise Figure 1 14 Adjusting Image Length 3 If the distance between points A and is gt 15 000 38 10 cm increase the Manual Length Adj value if the distance between A and is lt 15 000 38 10 cm decrease Manual Length Adj To adjust this value From the Main Menu on the control panel press the 4 key More Information Press 427 Calibrate e Press 1 Calibrate Transport e Press 2 Manual Length Adj Enter the amount to decrease or increase For example if the distance is 15 010 enter 010 Ifthe distan
153. hat your PlateStream is set up for i e 900 or 1200 DPI Use a page setup from the RIP that corresponds to this lowest resolution 2 With the unaided eye look at the 1x1 2x2 3x3 4x4 and 8x8 checkerboard patterns 3 Ifall 5 patterns look the same density the same grey level the image power is correct 4 Ifthe patterns get lighter grey going from 8x8 to 1x1 with 1x1 being the lightest the image power is set too low Increase the image power and run the file again Again look at the patterns to determine if the grey level is acceptable This image power is made from the op panel main menu as follows 1 Setup enter Verify that the resolution shown after 2 is the same as you ran the file at 3 Image Power type in a higher or lower image power setting number enter Then re run the file B 2 CALIBRATION 5 Ifthe patterns get darker grey going from 8x8 to 1x1 with 1x1 being the darkest the laser power is set too high Decrease the laser power and run the file again and again look at the patterns to determine if the grey level is acceptable 6 Repeat this procedure with the next highest resolution with the following exceptions At 1800 DPT ignore the 1x1 pattern as it will nearly always be too dark At 2400 DPI ignore the 1x1 and 2x2 patterns as they both will nearly always be too dark NOTE When changing image power at low resolutions it may take several power level changes before a change in grey level on t
154. he control panel Leading Edge Press 4 More Information Press 2 Calibrate Press 1 Calibrate Transport Adjusting Cut Length 1 Measure the distance between points C and D see Figure I 15 2 If the distance between C and D is gt 0 5 1 27 cm decrease the value for Cut Length Adj on the control panel by the difference for example if the measured value is 0 505 and Cut Length Adj is set at 1 955 then decrease Cut Length Adj to 1 950 3 If the distance between C and D is lt 0 5 1 27 cm increase Cut Length Adj by the difference Operator Side front of Platesetter C D Figure I 15 Adjusting Cut Length and Backup Length 1 22 INSTALLATION GUIDE Adjusting Backup Length 1 Measure the distance between points A and B see Figure I 15 2 If the distance between A and B is gt 1 200 3 05 cm increase the value for Backup Length Adj on the control panel by the difference for example ifthe distance between A and B is 1 250 and Backup Length Adj is set at 1 350 increase Backup Length Adj to 1 400 3 If the distance between A and B is lt 1 200 3 05 cm decrease Backup Length Adj by the difference 4 Recheck overlap by measuring the width of the black band at the leading edge of the plate 5 The width should be at least 0 050 0 13 cm 6 Ifa silver
155. he printed patterns is visible At higher resolution often times a change of 1 power level will result in a visible change in grey level on the printed patterns B Measuring Solid Black Areas a Runa calibration target or a test plate and measure the density ofa solid black areausing areflective densitormeter transmissive densitometer for film b SettheD according to the media manufacturer s recommendations referto manufacturer s documentation or see the following table Media Optimal D Film 3 50 0 20 SilverStream or AgfaSetPrint Plus 1 27 0 02 Mitsubishi Silver DigiPlate 1 34 0 02 The values in the table may be higher than the manufacturer s recommendations Because of the quality of its laser spot the PlateStream can be set higher to yield better solids without sacrificing fine lines d Ifthe calibration of the densitometer is at all suspect a rough procedure is to 1 fully fog a piece of plate material and 11 set laser to yield 06 below the fully fogged density reading e If the density reading is less than optimal increase the laser power If the reading 15 greater than optimal reduce the laser power Tip as arough rule of thumb change the laser power by 1 for each 01 density change needed We ve found that D at900 dpi is best set approximately 04 higher than the optimal f Repeat procedure for each resolution and media type You may prefer to calibrate only higher resolutions use
156. houlder screws located on solenoid underneath the shutter assembly Remove the following parts from the rear end of the Capstan roller shaft jam nut 2 wave washers spacer roller bearing bearing clip removing two hex nuts Remove the following parts from the front end of the capstan roller shaft pulley removing Allen screw bearing clip removing two hex nuts Access the Capstan roller from the top of the Platesetter Remove the five E clips Remove the roller by sliding the capstan roller toward the front of the frame until the rear of the roller shaft clears the frame Install the new Capstan roller in reverse order Lower the marker and close the top cover Replace the front and rear panels Replacing the Service Loop Exit Rollers See Figure S3 1 1 Open the top left cover and raise the marker assembly Remove the rear and front left panels 2 Rotate the belt tensioner down and then slide the long Imager Exit belt off the pulley 24 SERVICE MANUAL 3 Remove the pulley from the shaft by loosening the two set screws Remove the E clips and spacers if any from each end of the roller shaft Remove the bushings from each end of the roller shaft Access the upper roller from the hole in the front of the Platesetter Access the two shoulder screws holding the guide below the upper roller from the front and rear of the Platesetter and remove Remove upper roller by sliding towards the rear of the Platese
157. id seals Inspect the surfaces of the galvanometer window the reversing mirror spherical mirror and the folding mirror Refer to Figure 52 1 If no dust particles or other particles are present on the mirror surfaces reinstall the marker assembly unit lower cover If this is the case the cause of the plate quality problem is not mirror cleanliness If dust particles or other particles are present on the mirror surfaces then perform the following procedures CAUTION Do not touch the mirror surfaces with your fingers Perform this procedure only if 1 Dust particles can be seen on the mirror surfaces 2 Printed plates have silver vertical streaks or vertical lines with fuzzy edges Cleaning the Galvanometer Window Reversing Mirror and Spherical Mirror Using Com pressed Air 1 Hold the compressed air canister upright and direct the nozzle or extension tube toward any mirror surfaces that appear dusty 2 Gently blow the dust away Short quick blasts of air are more effective than continuous spray ing CAUTION The Reversing Mirror has the most fragile surface Its surface is preferrably cleaned only with compressed air Even gentle rubbing using a soft tissue may destroy its surface coating Perform this procedure only if 1 Dust particles can not be removed from compressed air see above procedure 2 Spots can be seen on the mirror 3 Plates have silver vertical streaks or vertical lines with fuzzy edges 11
158. ified number of plates have been imaged the displayed value will return to its selected value 2 Choose Pattern This selection sets the pattern The choices are Composite Pttrn Half Blk Wht All Black Plate Wide Vert Lines Thin Vert Lines Wide Horiz Thin Horiz Small White Sqs Small Black Sqs Large White Sqs Large Black Sqs Dark Gray Tone Light Gray Tone Press Pattern Horz Line Res Screen All White Plate Calib Screen 3 Choose Length Sets the length of the test plate The allowable range is 12 to 27 in processor mode and 2 to 27 in cassette or Miniplate modes CONTROL PANEL More Information Menu More Information ESC to exit 1 Run Hardware 8 Punch OFF 2 Calibrate 3 Status 4 Backup Feed Transport Miniplate Cut Length 12 7 Miniplate Backup ON Guide Sensor ON ESC OFF ENTER 1 Run Hardware Provides access to the Run Hardware menu 2 Calibrate Provides access to the Calibrate menu 3 Status Provides access to the Status menu 4 Backup Feed Transport Turns the capstan and feed motors on and backs up the media six inches This is used to clear media wrapped around the capstan roller see Clearing Media Path in chapter seven To stop capstan motor press ESC or OFF key 5 Miniplate Cut Length Only with Miniplate option installed Cuts the plate if accumulated Miniplate length exceeds this value Values are integer inches 12 13 14
159. inkled Cracked Plates Plates have Short Press Life 75 CAUSE 1 The exposure is set too high Bad plate material The press plate clamp is improperly set Press pressure is exces sive Press blanket surface is too harsh There are abrasive particles in the press ink The press ink fountain balance is incorrect The press ink is too tacky 6 Platesetter Processor chemistry is depleted 7 Marker out of focus SOLUTION 1 Adjust the exposure using the Platesetter Setup menu on the control panel 2 Replace plate material k Check handling techniques when mounting plates and check the uniformity of the plate clamp Adjust the pressure 2 Change to softer smoother blanket Replace the ink 4 Adjust the moisture control on the press to minimum 5 Replace the ink or add reducer 6 Change Processor chemistry 7 Call for service PROBLEM Toning Specking Background Smeared Images Tails on Charac ters Weak Image on Press CAUSE Plate media has abrasions The press ink is emulsified The press fountain solution is contaminated The Platesetter rollers are dirty Platesetter Processor chemistry is weak Plate media defective incom patible Too much press ink The press fountain solution is contaminated The roller pressure on the pr
160. ion punch and 2400 dpi values are applicable only if those options are installed Resolution 900 1200 1800 2400 Cut Length Overlap Length Backup Length Punch off Backup Length Punch on Punch Length Punch on Miniplate Backup Length Image Power Processor amp Mini Plate Image Power Cassette MT Speed 1 Turn off the Platesetter and open the top cover 2 Replace the controller PCA as follows 31 SERVICE MANUAL CAUTION Follow ESD protective procedures carefully Refer to page 1 1 neces sary a Remove the gold shield by unscrewing four screws and washers b Disconnect J1 the laser diode connector first and immediately connect the cable to the brown grounding connector located underneath the PCA on the right side of the marker assembly frame See Figure 54 1 This prevents damage to the highly sensitive laser diode c Disconnect all cables from the controller PCA Note the correct orientation of each cable d Unscrew the four standoffs holding the controller PCA Carefully remove the controller PCA from the top of the marker assembly by squeezing the five plastic standoffs holding the controller PCA Note Always transport and store PCAs in anti static bags 3 Install the new PCA in reverse order 4 Recalibrate the marker assembly controller PCA as follows At the main menu move the cursor to position 4 or simply press 4 to access the More Information
161. king tanks in the processor A 0 indicates the current level is okay a 1 indicates a low solution level in one or both of the tanks REPLN TANK LOW This sensor monitors the solution level in the replenishment tanks underneath the processor A 0 indicates the current level is okay a 1 indicates a low solution level in one or both of the tanks EFL TANK HIGH This sensor monitors the level of spent solution in the optional effluent tank underneath the processor A 0 indicates the current level is okay a 1 indicates the tank needs to be emptied PROC TEMP OK The processor Activator Temperature sensor monitors the temperature of the Activator bath A 0 indicates that the current temperature is okay a 1 indicates that the bath is still warming up or that there is a problem with the heater PROC EXIT Indicates the presence or absence of media at the processor exit sensor A 1 indicates that media is present e g during imaging A 0 indicates the sensor is clear This is the normal operating condition TAKE UP CASSETTE Identifies the presence of an optional film takeup cassette A 1 indicates the film takeup cassette is present A 0 indicates that the film takeup cassette is not present 2 16 PREPARING FOR OPERATION CHAPTER 3 Preparing to Make Plates Overview The following information explains how to prepare the Platesetter for a print
162. kk 10 11 12 13 Open the Imager top cover and remove the strips of bubble pack Remove tie straps and bubble wrap from struts Remove the caps on the outside of each strut head Detach the right cover strut on the marker end by removing the cap and pulling off the ball joint Locate the hinge shaft for attaching the marker assembly at the top inside left rear of the Imager Have two people lift the marker assembly from the carton Place the marker assembly in the Imager by placing the hinge brackets on the hinge shaft not on the brass bushings Slide the marker assembly mounting clip onto the right spring loaded brass bushing Lift the other end of the marker assembly and place it past the brass bushing Slide the brass bushing into place Remove the shipping brace located on the laser end of the marker by removing eight screws Save the brace and screws in case the platesetter or marker need to be returned to the factory Remove the 26 by 1 66 cm x 2 5 cm piece of black tape from the bottom of the marker assembly by gently pulling on the loose end of the tape To attach the struts to the marker assembly Raise the marker assembly until the ball joints on the outside line up with the strut heads Firmly push the strut heads onto the ball joints and reattach the caps to lock the struts to the marker assembly Gently lower the marker assembly and lock by pushing the marker lever towards the rear of the Platesett
163. lat cardboard cover with the four Styrofoam pieces facing up over the plastic bag Seal the carton e Bubble wrap and tie wrap the marker struts inside the Platesetter f Reattach the right cover strut by firmly pushing the strut head onto the ball joints and reattach ing the caps to lock the strut C Package the Imager 1 Remove customer supplied power plug Bubble wrap the end of the power cord 2 Remove the supply cassette Bubble wrap the media spools and place in the supply cassette Secure the shaft to the inside of the supply cassette with tape Bubble wrap and place in the accessory box 1 30 INSTALLATION GUIDE 3 Bubble wrap the two binders containing the manuals place items in accessory box and seal it shut 4 Close the Imager top cover Place three strips of bubble wrap on top of the front panel Place two DESI PAK bags on the Imager crate Roll the Imager up the ramp onto the Imager crate 5 Support the Imager up off of the wheels by a Placing the 18 by 6 3 4 34 cm x 17 cm wood block with lip underneath bottom front of the Imager The frame must rest on the foam b Placing the 18 by 6 3 4 34 cm x 17 cm wood block underneath the bottom back of the Imager The frame must rest on the foam c Placing the two 24 by 6 3 4 61 cm x 17 cm wood blocks underneath the bottom sides of the Imager The frame must rest on the foam Attaching all four wood blocks to the crate by using two wood screws in each blo
164. line appears increase the value for Overlap Length Adj on the control panel Adjusting Miniplate Backup Length Miniplate Backup Length can be used to adjust or eliminate the gap between Miniplate jobs It also adjusts the gap between jobs in the Cassette Mode 1 To turn Miniplate Mode ON from the Main Menu on the control panel Press 1 Setup Press 6 Destination Select Processor Miniplate as the output destination 2 To enable Miniplate Backup from the Main Menu on the control panel Press 4 More Information Press 6 Miniplate Backup Press ON to turn Miniplate Backup ON enabling calibration of the gap between Miniplate jobs Press 5 to select Miniplate Cut Length Set to the intended plate length e g 12 then press ENTER to save 3 To run a test plate from control panel Main Menu e Press 2 Test Plate Press 3 Choose Length Set to the approximate intended length of the Miniplate jobs e g 4 then press ENTER to save Press 2 Choose Pattern Use the ON key or the OFF key to scroll through the patterns Select the Screen pattern then press ENTER to save Press 17 Run XX Plates Enter the number of jobs per miniplate Press ENTER to image a Miniplate test plate Press ESC to return to the Main Menu 1 23 INSTALLATION GUIDE 4 To calibrate the gap
165. llowing 18 keys ON key OFF key an ESC key an ENTER key 4 arrow keys 10 numeric keys numbered 0 9 These keys allow you to perform a variety of functions To select an item move the cursor over the corresponding numeric key with the mouse and push the left mouse button to press the key To scroll through the choices of the selected item press the ON or OFF keys To change numbers in a selected item press the numeric keys or press the ON to increase the number and press the OFF to decrease the number To exit a selected item without saving changes press the ESC key To save changes to a selected item press the ENTER key key is pressed that has no effect the control panel will emit a beep The PC keyboard may also be used directly to operate the Control Panel To minimize the Control Panel click on the lower right corner of the Control Panel This will leave the display but eliminate the keypad DO NOT CLOSE the Control Panel program upper right corner box while the imager is operating This will cause the interface to crash and the imager to malfunction CONTROL PANEL Printware PlateStream 1 Setup 5 Load 2 Test Plate 6 Cut Fd 3 On Off Line 4 More Information On Line Idle A0000 1800 DPI PROC Setup Test Plate More Information 1 Image Negative Right Reading 1 Run 01 Plates 1 Run Hardware
166. llowing the manufacturer s instructions Fill the processor working tanks inside the Platesetter and the replenishment tanks with the solutions Remove the bubble pack from the replenishment probes located underneath the processor and insert probes into the replenishment tanks by screwing on the white cap Remove the bubble pack from the optional effluent probe located underneath the processor and insert probe into the small hole on top of the optional effluent tank INSTALLATION GUIDE Label the replenishment tanks and replenishment probes following the instructions supplied with the processor labeling kit note that the color codes are different for Mitsubishi and Agfa chemistry Attach one end of the 6 long 1 4 180 cm x 3 cm diameter vinyl hose to the drain underneath the processor If there is an optional effluent tank place the other end in the optional effluent tank Gently push the cart s under the processor Replace the right front panel Rotate the gears in the activator and stabilizer racks several times to free them up before operating the Platesetter Close the top covers Installing the Raster Image Processor RIP 1 Unpack the RIP central processing unit CPU and inspect it for any obvious physical damage If any component appears damaged notify the carrier immediately Unpack the RIP keyboard Unpack the RIP monitor Plug the monitor cable into the back of the RIP CPU this cable should fit only one w
167. m N N N N NN ND NHN WN BON DNDN BBB a ha a L 0 Q Assembly Number 807425 XXX ASSY PUNCH PS46 2 HOLE Number 8074 15 002 90105 1 005 90105 1 004 90105 1 007 90105 1 008 900940 003 900940 004 900940 005 901051 009 901053 001 807460 003 901052 003 807301 001 900235 000 806935 002 806957 001 900610 003 808210 001 808211 001 808230 001 807412 001 808213 001 808212 001 807091 001 806806 001 806269 001 900651 022 900651 020 900047 000 900445 007 900236 008 900235 002 900235 040 900233 003 900233 003 900235 000 900369 001 900287 029 900160 004 900005 002 900336 000 806915 002 Revision Component Description ASSY COMPRESSOR MODIFIED FITTING TUBE QUICK STRAIGHT FITTING TUBE QUICK STRAIGHT FITTING TUBE QUICK ELBOW FITTING TUBE QUICK STRAIGHT TUBING POLYURETHANE RED TUBING POLYURETHANE ORANGE TUBING POLYURETHANE GREEN FITTING TUBE QUICK BULKHEAD UNION MUFFLER PNEUMATIC ASSY PUNCH 2 HOLE SOLENOID AIR VALVE ASSY CABLE SOLENOID SCREW SHC 8 32 X 75 BRACKET PUNCH MOUNTING NON OPERATOR SIDE BRACKET PUNCH MOUNTING OPERATOR SIDE V SEAL BROWN GUIDE LOWER PUNCH GUIDE UPPER PUNCH PANEL I O PUNCHSTREAM BRKT PUNCH PLATE GUIDE UPPER CUTTER GUIDE LOWER CUTTER ASSY SWITCH ASSY CROSSOVER GUIDE PANEL FLAT SDP 1800 WASHER FENDER 5 X 189 X 125 WASHER FENDER 749 X 203 X 156 WASHER EXTERNAL LOCK 8 SCREW B H TORX 8 32 UNC X 500 SCREW SOCKET HE
168. mode Set the plate width from the control panel setup menu Optional Adjust the feet remaining feature on the control panel input spool manager menu 14 Push the load knob in This will automatically load the film material The control panel must be in the main menu or the test plate menu for this automatic feature to work NOTE Pressing the load key 5 on the control panel Main menu will also start the load film process Image one test plate from the control panel Test Plate menu The platesetter is now ready to image 15 To remove imaged film for processing press the Cut Fd 6 on the control panel Main Menu Open the processor top cover and remove the take up cassette by lifting the cassette off the two black take up receptacles 16 To remove film from the feed cassette open the load door and pull on the load knob Remove the feed cassette by lifting the cassette off the four black receptacles Open the feed cassette by lifting the back of the lid and sliding forward at the same time Remove the spool assembly from the cassette Remove the right hub from the shaft by lifting the clip and sliding it off of the shaft Slide media off of the shaft To load another roll of film media follow steps 1 through 14 outlined above Note The take up cassette will hold up to 25 of printed jobs however the cassette will hold only one piece of media at a time 3 11 PREPARING FOR OPERATION Emulsion out Emulsion in 5
169. must rest on the foam 4 Attaching all four wood blocks to the crate by using two wood screws in each block 5 Replace the front and rear panels Place three strips of bubble wrap on the front panel Plastic wrap the entire Processor Place the foam cap over the Processor Place the 33 84 cm wide plywood with notches on the front of the crate with the boards facing inside the crate and the notches on the bottom Place the 33 84 cm wide plywood on the back of the crate with the boards facing inside the crate Place the two 50 127 cm wide plywood on the sides of the crate with the boards facing inside the crate and flush with the bottom Screw the top and the sides together Make sure the top cover and the sides are very secure B Package the marker 1 29 1 Disconnect cables B Disconnect the grounding strap from the imager section frame b Disconnect the 10 wire connector from J6 on the printed circuit assembly PCA located on top of the laser marker assembly Disconnect the ribbon cables from J8 on the PCA and J9 on the PCA d Disconnect the orange and white wires from the connector located towards the front of the Marker next to the fan e Bubble wrap the ends of the disconnected cables e INSTALLATION GUIDE 2 Prepare to remove the marker a Raise marker by pulling marker lever towards the front of the Platesetter until lever stops and lift the front of the marker b Place a 26 by 1 66 cm x 2 5
170. n its resistance should be approximately 55 ohms If the ON ESC solenoid is open or shorted replace the solenoid OFF ENTER 4 2 If the solenoid is OK but not being actuated replace the interface PCA 4 3 Ifthe solenoid is actuating but the shutter isn t fully opening check that the moveable arm moves freely 4 4 If the moveable arm doesn t move freely loosen the screws that control the arm until it moves freely 53 SERVICE MANUAL GENERAL IMAGER PROBLEMS cont Light leaks 1 models with load door the door is the most common source of light leaks Open the load door and look down to the bottom of the chassis Shine a flashlight into the gap between the load door and the bottom skirt If light is visible seal the gap between the load door and the bottom skirt with black electrical tape On models without a load door check the light seals around the panels and cassettes with a flashlight Move the platesetter away from bright light sources such as windows If this is not possible orient the platesetter with the processor end is away from light sources If unable to resolve the problem send sample plates to Printware Send 22 long plate with a gray test pattern 54 SERVICE MANUAL GENERAL IMAGER PROBLEMS cont No media or 1 Verify that there is media in the machine Media not loaded far enough 2 Manually feed the media up to the capstan roller me
171. n loaded but no plates have been imaged yet Imager is in cassette mode and 21 plates have been imaged so far Setup ESC to exit 2 Input Spool A Destination Processor Display Units English 1 Image Negative Right Reading 2 Resolution 800 DPI 1 Image Power 2 5 6 yi 5 Media Width 13 12 Spool Pos 13 ON ESC OFF ENTER 1 Image This selection sets the type of imaging for the different types of media The choices are Positive or Negative Wrong Reading and Positive or Negative Right Reading These attributes can be set separately for Cassette mode and Processor Miniplate mode For example cassette mode could be set for Positive Wrong Reading the destination could be changed see item 6 below and Processor set for Negative Right Reading Cassette mode would remain Positive Wrong Read ing in this example 2 7 CONTROL PANEL 2 Resolution Sets the resolution of plates imaged from the control panel The choices are 900 1200 1800 or 2400 dpi Note that this menu only affects test plates sent from the control panel the resolution of plates sent from the front end or RIP are set by the RIP The message Not allowed Imager and or RIP busy appears if jobs are running while attempting to change resolution 3 Image Power Sets the image power laser intensity Increasing image power increases D or Density while decreasing image power reduces D Image power be se
172. n setting storing procedures Recalibrating the Marker Controller PCA At the main menu press 4 to access the More Information menu Press 2 to access the Calibrate menu Press 2 to calibrate Marker The control panel will display are you sure Pressing ESC exists this menu without changing the marker calibration Pressing ENTER will cause the control panel to display Power Cycle which means to turn the machine off then back on 27 SERVICE MANUAL CHAPTER 4 REPLACING ELECTRONIC COMPONENTS Introduction Signals output by the RIP are received by the controller PCA mounted on top of the marker In structions and acknowledgments are acted on accordingly The controller PCA controls power to the laser and drive current sent to the galvanometer The data signals sent to the controller PCA cause the circuitry to turn the laser on and off while the galvanometer sweeps the laser light back and forth across the plate surface to selectively expose portions of the plate material passing under the aperture The engine stepper PCA precisely controls the timing of drive signals sent to the various motors within the Imager section to coordinate the feeding imaging and cutting of the plate material The control panel PCA accepts signals from the interface PCA controller PCA and from the hu man operator via the keys on the control panel to control and report Platesetter functions and conditions There are fo
173. n this case a message will appear on the operator panel to Reload Media or Manually Reload Media EMULSION OUT MEDIA EMULSION IN MEDIA Spools Right Hub Right Hub Left Hub Left Hub S Media Roll P i Position 18 5 Position 18 Figure I 2 Loading Plate Media on Spool I 12 INSTALLATION GUIDE Setting Replenishment Rates 1 Open top cover and remove replenishment hoses from the working tanks inside the processor Place the replenishment hoses in measurement containers 2 From the control panel run a test plate that represents the average plate size that will be run on this Platesetter 3 Compare the measured volume to the table outlined below Recommended replenishment rates are as follows Printware SilverStream Activator or Stabilizer 0 37 ounces ft 120 ml M Agfa Setprint Plus Activator or Stabilizer 0 37 ounces ft 120 ml M Mitsubishi Silver DigiPlate Activator 0 47 ounces ft 150 ml M Stabilizer 0 63 ounces ft 200 ml M Average Plate Size 0 6 fi 0 8 f 1 0 f 1 2 fe 1 4 f 1 6 fe 1 8 f 2 0 f 2 5 ft 0 06M 0 07M 0 09 0 11 0 13 0 15 0 17 0 19 0 23 Printware SilverStream Activator amp Stabilizer oz Activator amp Stabilizer ml Agfa Setprint Plus Activator amp Stabilizer oz Activator amp Stabilizer ml Mitsubishi Silver DigiPlate Activator ounces Stabilizer ounces Activator milliliters Stabilizer milliliters 5 If m
174. nations of all the sensor indications are shown below This menu is provided primarily for trained techni cian use LOAD KNOB This sensor is activated when the load knob is pushed A 0 indicates the load knob is pushed in 1 indicates the load knob is pulled out FEED LOOP Indicates the status of the service loop sensor in the feed area of the Platesetter T indicates that a loop is formed 0 indicates that a loop is not present EXIT LOOP Indicates the status of the exit loop sensor in the exit section of the Imager 17 indicates that a loop is formed 0 indicates that a loop is not present IMAGER EXIT Indicates the presence of media at the imager exit A 1 indicates that media is present e g during imaging A 0 means the sensor is clear this is the normal idle condi tion NO MEDIA Identifies the amount of media in the spool as okay or none 0 indicates that the media supply is empty 1 indicates that the amount is sufficient 2 15 CONTROL PANEL LOAD OK Indicates the status of media loading A 1 indicates the media is loaded a 0 indicates the media is not loaded GUIDE Indicates the presence of media at Guide A 1 indicates that media is present e g during imaging A 0 indicates the sensor is clear This is the normal idle condition WRKNG TANK LOW This sensor monitors the solution level in the wor
175. ning the Imager Rollers Clean all the Imager rollers when necessary to prevent plate slippage or plate skew It s easiest to clean the rollers just after the spool has run out of media To clean these rollers 1 Open the imager top cover Raise the marker by pulling marker lever towards the front of the Platesetter until lever stops Lift up marker gently see Figure 6 1 Imager Cover y Lever Marker Dryer 3 Cover G eres Processor Guide A Capstan Roller Working Tanks Load Knob E 9 x e 1 Wi Guide C2 pins Guide D pins 1 Guide pins Y e ut Er mr n ae am a NE L Processor exit Guide B pins S Esos 1 Guide pins Activator Stabilizer Effluent Drain gt A Optional Effluent Tank Tank amp Cart Optional GU C 2 Replenishment Tanks Cart Optional Figure 6 1 Side View of the PlateStream 46 Platesetter 6 3 PREVENTIVE MAINTENANCE 333 SI I N CAUTION Be very careful when working on or around the Imager rollers with the machine running especially when wearing a tie or loose fitting sleeves to avoid getting anything caught between the rollers oe oe oe oe 2 From the Main Menu display on the control panel press 4 and then 1 to access the Run Hardware Menu 3 Turn on the feed motor by pressing the 1 key and then the ON key Access the feed
176. not stick ing 3 If Sensor Status does ON OFF ESC ENTER not toggle between 1 and 0 the switch should be replaced The replacement part includes detailed re placement instructions Sensor status menu 58 SERVICE MANUAL CUTTER PROBLEMS Cutter won t cycle Cutter won t stop cycling Cutter cycles but doesn t cut 59 Check and re seat cutter connector Check for loose wires on the cutter switch non operator side of machine See if the cutter motor shaft spins by hand the shaft coming out of the back of the motor Check for any media stuck in cutter Check motor winding resistance normally 10 to 1000 If motor is shorted or open replace the cutter Switch misadjusted 1 1 If switch is open the cutter wheel should turn one third of a revolution 1 2 If switch 15 activated the wheel should turn 2 to 4 revolutions without stopping Switch failed 2 1 Turn the shaft on the back of motor by hand you should be able to hear the switch click 2 2 Check the switch with an ohmmeter in the open and closed positions Remove cutter assembly so cutting blade can be adjusted Lay cutter on a table with cutter blade facing up Turn blade by spinning silver shaft on back of motor by hand clockwise until blade comes down to lowest point in its rotation Loosen set screws on arm with a metric Allen wrench Rotate cutter blade shaft on opposite en
177. ns and remove Wash cover G and dryer rack in warm soapy water and dry using a soft cloth Replace dryer rack and cover G to original position 5 Close top cover 6 5 IN CASE OF TROUBLE CHAPTER 7 TROUBLESHOOTING Print Quality Troubleshooting PROBLEM CAUSE SOLUTION Scumming ghost 1 The press ink fountain Correct the balance images smudges or balance is incorrect blotches on prints due to poor plate surface 2 The press fountain mix 2 Use the recommended fountain solution ture is incorrect or too properly mixed weak 3 The press ink is not com 3 Use the recommended ink patible with the other chemicals 4 The press dampener 4 Adjust the pressure form roll pressure is out of adjustment The press Moleton PONE 5 Replace the cover or sleeve or sleeve is contami nated 6 The Platesetter Processor 6 Replace Platesetter Processor chemistry chemistry is depleted 7 2 IN CASE OF TROUBLE PROBLEM Image Blinding faint printing 7 3 CAUSE 1 The press ink fountain bal ance is incorrect 2 The press pressure is insuf ficient 3 The press ink rollers are glazed 4 The paper is clinging to the press blanket 5 The press fountain concen tration is too strong 6 The press blanket was not dry on roll up 7 The press blanket is glazed SOLUTION 1 Check the balance and correct if necessary Check the pressure and cor rect if n
178. ntroller PCA Calibrate the marker Replace the controller PCA Check the laser diode J1 and the safety interlock J7 connectors on the controller PCA Calibrate the marker Replace the controller Check SOS SOT connectors on the controller PCA Check SOT sensor alignment Calibrate the marker Replace controller Replace marker assembly Calibrate the marker Replace the controller 50 SERVICE MANUAL MARKER GALVANOMETER PROBLEMS cont Marker hold error message 51 1 Turnup fogging circuit clockwise turn maximum Note original potentiometer position If resetting does not alleviate problem return to original position 2 SOS and SOT sensors Turn SOS screw 1 full turn clockwise Turn SOT screw 1 full turn counterclockwise Note original screw positions If realigning sensors does not alleviate problem return to original positions 3 Replace marker assembly GENERAL IMAGER PROBLEMS Platesetter spontaneously reboots Power out of spec message Platesetter is on line but will not start a job On Dual Cassette model Lower cassette unload does not stop after switching to upper cas sette N Re POE SERVICE MANUAL Check AC voltage The specification is 200 264 Volts 50 60 Hz Protect against AC power glitches 2 1 Check for correct AC power wiring especially grounding 2 2
179. nu see chapter 2 in the section Setup Menu The minimum job length is 1 Miniplate accumulates shorter jobs until the combined length of the jobs exceeds an operator selected cut length e g 12 The plate material is then cut and run through the processor Miniplate cut length can be set from 12 to 18 in the More Information Menu see chapter 2 The gap between jobs in Miniplate Mode can be eliminated or set to a desired amount in the Calibrate Menu see the Physical Calibration section of the INSTALLATION GUIDE This calibration is enabled in the More Information Menu Miniplate mode can also be used in cassette mode to eliminate the gap between jobs The CUT Fd key 6 operation will cut and feed into the processor any miniplates remaining in the Platesetter The extra material fed to bring the length up to the selected minimum length will be imaged black so as not to pick up ink on the press The word MINI in the lower right corner of the main menu indicates that the Platesetter contains miniplates that have not been cut or processed The following digit indicates the number of miniplates in the Platesetter and if more than 9 miniplates are present the digit will be replaced by a Printware PlateStream 46 Setu 5 Load Plate Test 6 Cut Fd On Off Line More Information n Line Transporting A0075 1800 DPI MINI3 ON ESC OFF ENTER 3 9 PREPARING FOR OPERATION Film Option With this
180. ocused down to a small point when it strikes this mirror and is therefore susceptible to interference from dust or other surface dirt Procedures to Determine if the Mirrors Need Cleaning Ensure that all Platesetter Recommended Periodic Maintenance has been performed Examine the Platesetter output The most likely indications of dirty mirrors are light vertical streaks of varying width and vertical lines with fuzzy edges Turn off the Platesetter Open the top cover and raise the marker assembly Inspect the folding mirror through the marker assembly cover aperture using a flashlight See Figure 52 1 Examine the mirror for dust Cleaning the Folding Mirror Using Compressed Air CAUTION Do not remove the Marker Cover at this time Do not touch the mirror surface with your fingers Perform this procedure only if 1 Dust particles can be seen on the Folding Mirror 2 Printed plates have silver vertical streaks or vertical lines with fuzzy edges 1 Hold the compressed air canister upright and direct the nozzle or extension tube toward the mirror surface 2 Gently blow the dust away Short quick blasts of air are more effective than continuous spray ing SERVICE MANUAL Getting authorization to remove the Marker Lower Cover On the marker lower cover are two seals which read Warranty Void If Seal Broken Refer to Figure 52 1 In situations where the marker is under warranty the warranty will be void if the marker
181. of rollers and 2 edge guides 7 Rotate the cassette up and lock into place on the platesetter Be sure the media is not pinched between the cassette and the platesetter 8 From inside the platesetter push the media up through the next edge guides and into the nip of the pinch roller 9 Set the front edge guides up against the media and tighten the screw 10 Gently lower the marker and lock down by pushing the marker lever towards the rear of the platesetter until the lever is horizontal Close the top cover 11 Set the plate width from the control panel setup menu Optional Adjust the feet remaining feature on the control panel input spool manager menu 12 Push the load knob in This will automatically load the plate material The control panel must be in the main menu or the test plate menu for this automatic feature to work NOTE Pressing the load key 5 on the control panel main menu will also start the load media process 13 Image one test plate from the control panel Test Plate menu 1 14 INSTALLATION GUIDE NOTES Destination must be set to Processor see the PlateStream 46 Platesetter Operator Manual for control panel procedures Cut off any punched area of plate before reloading to ensure a reliable load Remove leader from daylight load media before loading media Media must be loaded with no tears or wrinkles Media must be reloaded after jams or other fault conditions I
182. of the pulley Take care not to damage the wiring Remove the drive gear from the drive motor by loosening the two hex set screws in the gear 4 Open the top right cover Remove the driven gear from the drive shaft worm gear by loosening the two hex set screws in the gear Slide the gear off of the drive shaft worm gear while pushing the shaft to the left This allows the gear to clear the opening in the sheet metal 5 For 60 Hz installation the smaller gear 18 Teeth goes on the drive motor and the larger gear 20 Teeth goes on the drive shaft worm gear For 50 Hz installation the larger gear 20 Teeth goes on the drive motor and the smaller gear 18 Teeth goes on the drive shaft worm gear 6 When installing the gear on the drive shaft worm gear move the shaft all the way to the right Center the gear in the sheet metal slot Tighten the two set screws Make sure that one of the screws is on the flat of the shaft 7 When installing the gear on the drive motor push the gear onto the shaft leaving 0 04 1 mm between the gear and the motor housing Tighten the two set screws Make sure that one of the screws is on the flat of the shaft Seat the belt onto the driven gear and motor gear while twisting the motor into position Reinstall the two drive motor leads motor ground wire and 3 drive motor screws 8 Reconnect the power cord 9 Turn on the Platesetter From the operator panel start the processor press 4 1 8 Observe that the b
183. oltages Supplied to Controller PCA 5 VDC to power all integrated logic chips 24 VDC 12 VDC 12 VDC Connector Assignments Laser power and control J2 Not used J3 Not used J4 Not used J5 Not used J6 Power J7 Laser safety interlock switch J8 Imager Processor Interface J9 Interface PCA control panel communication cable J10 Galvanometer control J11 SOS SOT sensors J15 Not Used J16 Not Used 30 SERVICE MANUAL Replacing the Controller PCA The non volatile SRAM on the controller PCA stores the total plate count image quality settings image position settings and marker assembly calibration values All of this information will be lost when the controller PCA is replaced If possible look through all the menus on the control panel before replacing the controller PCA and write down all the settings Image quality and position settings can be re entered from the control panel after the PCA is replaced The plate count and material used count will start over from zero so keep a record of the values read from the old controller PCA with the Platesetter The marker assembly calibration values will be regenerated during the marker assembly calibration procedure If the image settings and plate count values cannot be read due to a massive controller PCA failure use the information from the customer s operator log for resetting these values Before beginning the replacement procedure record the following informat
184. on linting soft cotton cloth Cleaning refreshing chemical Recommended type is D Ink Processor Rollers Non linting soft cotton cloth Warm soapy water SERVICE MANUAL Printware Recommended Periodic Maintenance Schedule Recommendations based on 8 hours per day use 5 days a week 1 Imager section maintenance Weekly Roller cleaning damp cloth light D ink no alcohol or solvents Q Clean or replace fan filter General cleaning of dust dirt from imager area Clean out any punch chips from punch area or machine Check oil level in punch compressor 2 Processor section maintenance Weekly Remove Activator and Stabilizer racks Clean racks and guides with warm soapy water Do not use alcohol or solvents Clean any splashed chemistry from processor and dryer area Inspect racks for worn or damaged components gears and replace as necessary At 4 000 plates or 4 weeks whichever comes first completely drain Activator and Stabilizer tanks and clean tanks and racks Refill with fresh chemistry Note Replenishment rates are to be set to Printware recommendations See Setting Replenishment Rates in the Installation Guide Check the temperature of the Activator bath 86 F 2 3 Semi annual Preventive Maintenance LJ Performed by Printware authorized service technician Includes check and adjustment replacement as necessary of sensors and belts all bearings gears roll
185. on the rollers The processor should be cleaned more frequently if needed to maintain plate quality For Mitsubishi Silver Digiplate the processor should be cleaned if the pH of the chemicals fall outside the recom mended range Activator pH gt 12 8 Stabilizer pH lt 6 8 To clean the processor see figure 6 1 1 Open the processor top cover Place 6 long 1 4 diameter 182 cm by 3 2 cm vinyl hose from underneath the processor in the optional effluent tank Drain the processor working tanks by removing the overflow tubes located in the rear of the processor tanks inside the Platesetter Remove cover E Remove guide F by pressing guide towards the back of the Platesetter lift guide from the front of the Platesetter and remove Remove guide D by pressing guide towards the front of the Platesetter lift guide from the back of the Platesetter and remove Wash cover E guide F and guide D in warm soapy water and dry using a soft cloth Remove Activator and Stabilizer racks Clean the processor working tanks using warm soapy water and dry with soft cloth Clean Activator and Stabilizer racks using warm soapy water Rotate the rollers and clean them using a soft cloth and warm soapy water Replace the Activator and Stabilizer racks to original positions Replace guides and cover to original position 4 Remove cover G Remove dryer rack by holding the metal edge in the center of the dryer rack lift to clear the two bottom pi
186. oop Intermittent artifacts beginning approximately 2 down the plate Adjust the Feed Loop switch 2 2 Exit loop Intermittent artifacts beginning approximately 8 to 10 down the plate Adjust the Exit Loop switch 3 Traction control if installed may be jumping This causes irregular horizontal lines 3 1 Increase the belt tension by wrapping the spring around one additional turn 3 2 Temporarily disable traction control to see if this solves the problem 4 Noisy capstan motor causes high frequency horizontal banding down the whole length of plate 4 1 Check capstan motor mounting 4 2 Replace capstan motor 5 Noisy power supply fan Artifact will be a constant frequency down the page 5 1 Check fan motor mounting 5 2 Replace power supply fan motor 6 Ifunable to diagnose the problem send two plate samples to Printware for analysis Vertical artifacts 1 Wavy vertical lines throughout media or more severe on the non operator side of plate generally low frequency on the order of 10 artifacts per inch Usually a faulty galvanometer Replace marker assembly 2 Wavy high frequency on the order of 100 artifacts per inch vertical lines concentrated in the middle of the plate Usually a faulty controller PCA 3 Well defined straight vertical lines Usually faulty controller PCA 45 SERVICE MANUAL IMAGE QUALITY PROBLEMS ARTIFACTS cont Fuzzy or Blurry Image 1 Clean processor and replace ch
187. opened or closed use the Processor front right caster to raise or lower the Processor Open accessory boxes and remove bubble pack from contents The contents should include a A PlateStream 46 Platesetter Quick Start Guide Installation Guide Operator Manual and Service Manual A small replenishment cart and tank A wire tray and tray stops Optional take up and supply cassettes Optional punch chip collector and punch hoses Tube with plate samples Optional effluent cart and tank Black tank cover input guide crossover guide and overflow tubes ro INSTALLATION GUIDE Joining the Imager and Processor Modules 1 Before Joining the two modules route the processor power cable through the hole in the lower portion of the chassis and make the appropriate connections to the power supply Align the pins in processor module with the holes in the imager module Remove the plastic bag taped to the inside front of the Imager which contain the four sets of hardware 9 16 x 1 bolts to attach the Processor to the Imager Bolt the Processor to the Imager modules together using the four clearance holes located on the left side of the Processor and threading into the four threaded holes located on the right side of the Imager Replace the Imager front and rear panels Route the processor ribbon cable to the connector on the left side of the processor Plug in the three pin connector labeled EXIT CAS
188. ore replenishment is required turn the screw on the pump clockwise if less replenishment is required turn the screw counterclockwise The screw for the stabilizer replenishment is located towards the front of the pump the screw for the activator is located towards the back of the pump The adjustment screw has a ten turn range 6 If the average plate size changes the replenishment rate should be adjusted 1 13 INSTALLATION GUIDE Changing Processor for 50 60 HZ Operation Note The processor should be properly configured at the factory This procedure is included for refer ence only Refer to figures I 3 and I 4 The AC motor that runs the Processor will run 5 6 of the speed at 50 Hz than at 60 Hz The Processor speed can be adjusted by changing the drive and driven gears in the processor The motors in the imaging section are microprocessor controlled and are not affected by the AC line frequency 1 Unplug the power cord 2 Remove the wire tray located on the right side of the Platesetter Remove the right exit panel by unscrewing the four screws holding this panel Remove the front right cover Remove the gear access plate by unscrewing the six screws holding this panel 3 Remove the drive motor by unscrewing the three screws holding the drive motor to the chassis Discon nect the two drive motor leads and unfasten the motor ground wire Take the drive belt off of the drive shaft by rotating the shaft and deflecting the belt off
189. ount there is a separate set of Backup Length values with the punch enabled Decreasing the values decreases depth 6 If necessary follow the procedure for all resolutions to be used with the punch mode Punch length is set independently for each resolution Punch Notches Larger punch length produces deeper notches Figure I 16 Adjusting Punch Length 1 27 INSTALLATION GUIDE De Installing the Platesetter These instructions are provided in the event you ever need to repackage the Platesetter 1 Turn off the Platesetter and RIP 2 Disconnect the Imager cable from the rear of the Platesetter Packaging the Platesetter A Package the processor section 1 Open the top right cover and remove the optional film take up cassette Bubble wrap the cassette and place in accessory box 2 Drain processor a Remove the right front panel and gently roll out the effluent cart Drain the effluent cart Reinstall the effluent tank and place the 6 long 114 diameter vinyl hose from underneath the processor in the optional effluent tank Drain the processor working tanks by removing the overflow tubes located inside the Platesetter top section to the rear of the processor tanks 3 Clean processor a b Remove cover Remove guide D Press guide towards the front of the Platesetter lift guide from the rear of the Platesetter and remove Remove guide F Press guide towards the rear of the Plates
190. ower Switch gt T 24 60 cm Rear I O panel ea right clearance x 55 Supply Cassette _ 52 di 132 em 24 60 cm front clearance Figure 51 2 External Features of the PlateStream 46 Platesetter Construction of the Platesetter The five major component areas of the Platesetter are Imager Assembly The Marker The Power Supply Assembly Cables and Electronics Processor Imager Assembly The Imager Assembly consists of the following Spool Assembly Feed Rollers and Stepper Motor Drive System Capstan Roller Left and Right Pinch Rollers Capstan Pinch Roller Stepper Motor Drive System Cutter Upper and Lower Imager Exit Rollers and Stepper Motor Drive System SERVICE MANUAL Marker This section consists of the following Marker Assembly Includes Laser Diode Laser Lens Assembly Galvanometer Mirrors SOS and SOT Sensors Power Supply Assembly The power supply assembly consists of the following Power On Off Switch 220 Amp Circuit Breaker Electromagnetic Interference EMI Filter Power Distribution PCA Cooling Fan Multi output Power Supply External Connectors J1 J5 Cables and Electronics This group of components consist of the following Controller PCA Interface PCA Control Panel PCA Processor PCA Stepper Motor PCA Processor This group of components consist of the following Activator Tanks and Rack With Rollers Stabilizer Tanks
191. possible solutions Ensure that destination is set to Processor then Calibrate the processor by pressing ENTER The Platesetter must be in Processor mode not cassette or Miniplate mode to calibrate the processor For more details on menu items 2 7 see Physical Calibration in the INSTALLATION GUIDE 2 Manual Length Adj Incremental corrections to obtain the correct plate length The length change displayed is reset to 0 after pressing enter There are independent adjustments for each resolution At 900 dpi the manual length is adjustable in 0 006 0 015 cm increments at 1200 dpi in 0 004 0 01 cm increments 1800 dpi in 0 003 0 08 cm increments and at 2400 dpi in 0 002 0 005 cm increments 3 Cut Length Adj Sets the length of the trailing edge of the plate 4 Overlap Length Adj Sets the length of plate that is double exposed on the leading edge 5 Backup Length Adj Adjusts the length of the leader there is a second set of values with the punch option installed 6 Punch Length Adj Only with the punch option installed Adjusts the punch position on the plate 7 Miniplate Backup Length Adj Only with the Miniplate option installed Calibrates or elimi nates the gap between jobs in Miniplate mode 2 13 CONTROL PANEL Input Spool Manager Menu Input Spool Manager ESC to exit Spool A 1 2 Spool d Spool C Spool D ON ESC OFF ENTER 1 Spool A
192. ral menus 5 Load This selection loads the media 6 Cut Fd This selection cuts and feeds the media into the processor for the Miniplate option This selection cuts and feeds the media into the takeup cassette for the film option 7 The bottom three lines lines 6 8 of the Main Menu and Test Plate Menu display the current state of the Platesetter and any error conditions Line 5 displays the marker state only if the marker is not ready to print Line 5 Scan point 10 Current marker state displayed only during a marker error or while the marker is either calibrating or initializing On Line Idle Current imager state the messages displayed as a single plate is fed through the Platesetter in processor mode are On Line Idle Imager ready to start imaging imager and processor are idle except possibly for the last several inches of the last plate exiting the processor On Line Busy Imager communicating with the RIP On Line Backing Backing up leader of plate from cutter to start of image point On Line Marker Hold Marker getting ready to image On Line Imaging Imaging current plate On Line Image Leader Imaging leader of next plate On Line Advancing Advancing plate to cutter On Line Cutting Cutting plate On Line Punching Punching Plate CONTROL PANEL On Line Transporting Moving media out of the imager On Line Ready Pause 0 5 sec pause between plat
193. rated on a Printware Laser Imaging System and an IBM compatible PC CAUTION The electronic circuitry inside the Platesetter is very sensitive to damage from electrostatic discharge ESD Always follow the ESD protective procedures described in this manual when working on the Platesetter FEDERAL COMMUNICATIONS COMMISSION FCC NOTICE Printware Platesetters generate and use radio frequency If not installed properly a Platesetter may cause interference to radio and television reception Printware Incorporated complies with the limits for a Class A computing device in accordance with the specifications in Subpart J of Part 15 of FCC rules These rules are designed to provide reasonable protection against radio and television interference in a commercial installation The user can determine if this equipment is causing interference to radio or television reception by turning the Platesetter off and on Listed below are measures the user can take to correct the interference a Reorient the receiving antenna b Relocate the Platesetter with respect to the receiver c Move the Platesetter away from the receiver d Plug the Platesetter into a different outlet so the Platesetter and receiver are on different circuits If these measures do not correct the interference problem the user should consult the dealer or an authorized technician for additional suggestions CONTENTS Chapter 1 General Information Introduction au u 1 2
194. rker Focus Adjustment 12 Processor SOCOM miii ou ax 14 Chapter 3 Component Repair and Replacement Replacing Rollers Belts Motors and Cutter 20 Replacing Marker 4 2 27 Chapter 4 Replacing Electronic Components INTFOCUCTION 28 Controller dic 29 Interface ROA Sta u aQ a cbe A 32 Engine Stepper PCA let 34 Power Supply 37 SONS S Hurra ed 38 Chapter 5 Troubleshooting NN ii rn a Teea 42 Exposure Problems ese tee eos 43 Image Quality Problems Artifacts 45 Registration and Skewing 47 SERVICE MANUAL SERVICE MANUAL Operator Panel Problems 49 Marker Galvanometer 50 General Imager 52 Media Jams Imager Module 57 Imager Module Sensor Problems 58 Cutter Problems a a 59 Punch Probl ms Si yn Sul 60 Processor 62 Processing Quality Problems Artifacts
195. rker is not ready to image SOLUTION 1 Turn the Platesetter off wait 30 seconds turn Marker not ready the Platesetter back on and wait for the power up y to be completed 2 Call for service CAUSE The take up cassette is not installed while the Platesetter is in the optional cassette mode SOLUTION Install the take up cassette See chapter 3 in the section Film Option CAUSE The take up cassette for the film option is full SOLUTION Empty take up cassette See chapter 3 in section Film Option Takeup Full 47 SUPPLIES CHAPTER 5 SUPPLIES Introduction Using recommended supplies assures high quality printing plates and printed output The Platesetter is designed to image silver halide coated plate material The Image default for silver halide material is negative right reading See chapter 2 in the section Setup Menu Plate media may be either paper or polyester based Roll width may be from 9 to 18 1 22 9 cm to 46 cm The maximum roll length is 280 85 M SUPPLIES PRINTWARE SILVERSTREAM RED LIGHT PLATE MEDIA Emulsion In 5 mil polyester 808555 XXX 280 FT ROLLS 8 mil polyester 808666 XXX 280 FT ROLLS CHEMISTRY ACTIVATOR 808777 001 STABILIZER 808777 002 AGFA SETPRINT PLUS RED LIGHT PLATE MEDIA Emulsion In 5 mil polyester SET R 0 13 8 mil polyester SET R 0 20 CHEMISTRY ACTIVATOR 05200 STABILIZER 55400 MITSUBISHI SILVER D
196. ryer drive clutch is not slipping or the dryer rollers are rotating slower than the solution rack Tighten the dryer clutch by turning the nut at the end of the shaft clockwise 4 Check to see that there is a slight 0 01 to 0 03 0 03 to 0 08 cm end play in the rack rollers To adjust for this play loosen the set screws in the gears moving the gears on the roller shafts and tighten set screws 5 Check the dryer belts for wear or cracks 6 If there is excessive vibration check for damaged motor mounts 7 Check to see that rack gears are properly seated into the drive shaft worm gear The teeth should be engaged at least half way but not be bottoming out The drive shaft can be adjusted by loosening the bearing block screws at each end adjusting the shaft position and tighten block screws 8 Check and tighten hose clamps 15 SERVICE MANUAL 9 Check drain and replenishment line for restrictions 10 The drive motor replenisher pump motor and the blower motor do not need to be lubricated 11 Drive motor assembly removal Remove the wire tray located on the right side of the Platesetter Remove the right exit panel by unscrewing the four screws holding this panel Remove drive motor by unscrewing the three screws holding the drive motor plate to the chassis Disconnect the 2 drive motor leads and unfasten the motor ground wire Take the drive belt off of the drive shaft by rotating the shaft and deflecting the belt off of the
197. s for each resolution screen and media combination to be calibrated You may need to calibrate only those combinations you use for critical work B 5 HALFTONING AND SCREENING APPENDIX C Halftoning Printware RIPs provide a number of options to control halftone generation Using them appropriately can improve the quality of your image This section gives an overview of halftoning see the RIP manual for more details Halftoning is the process of approximating gray levels or color shades with a pattern of dots In many halftoning systems the dots can have only one color value but can vary in size to alter the ratio of dot color to background color The simplest use of this technique is approximating gray levels with a pattern of black dots against a white background as illustrated in Figure ApB 1 Here the size of the dots varies to represent different shades of gray You see an area of small dots as a light gray while an area of larger dots each nearly filling its allowed space in the pattern of dots is seen as dark gray More strictly it is not the size of the dots but the resultant ratio of black area to white area that represents the gray value Color shades are approximated with three patterns of dots each in a primary color cyan ma genta and yellow used with or without a fourth pattern of black dots This description of halftoning assumes three patterns in fact the fourth pattern of black dots is almost always used
198. sembly order both and have them wired together at the factory before shipment 60 SERVICE MANUAL PUNCH PROBLEMS cont Media gets stuck in punch 1 Clear chips from the system 1 1 Ifa vacuum cleaner is available attach it to the punch plate plumbing to extract any build up of chips this may be operator or non operator side depending on the chip collec tor configuration 1 2 If a vacuum cleaner is unavailable or step above doesn t clear the chips completely remove upper infeed Guide A the lower infeed guide with brackets left on the guide and the plate on the back of the punch to clear the remaining chips Be sure to reinstall the guide in the correct position 2 For older systems consider a vacuum chip clearing assist upgrade 2 1 The current design has the chip collection bag on operator side no upgrade neces sary 2 2 Systems with a vacuum assist upgrade have a fitting on operator side of the punch back plate to blow chips towards the non operator side vacuum tube Double punch with twisted plate 1 This problem is caused by a hooked edge of the punch pattern snagging the plate 1 1 Adjust punch side to side so that only complete holes are being punched This may require a press adjustment 1 2 Use wider or narrower media so that only complete holes are being punched Overheated compressor 1 Check oil level oil could have leaked out if the compressor had been tipped 2 Ch
199. sembly too high in front diagonal D E lt diagonal C F Turn adjustment screw clockwise to correct Leading Edge UJ i Open Top Cover Laser Marker Assembly Fixed point gt S G c D o ce o LL Capstan Roler Media Front Operator Side Operator Side front of Platesetter G I Figure 1 12 Image Skew Laser marker assembly too low in front diagonal D E gt diagonal C F Turn adjustment screw counterclockwise to correct INSTALLATION GUIDE Scan Width and Linearity Adjustment Leading Edge This procedure enables you to fine tune the imaging accuracy and the positioning of the laser beam The B overall width of the image on the plate is determined by the positions of two sensors accessible from the front operator side of the laser marker assembly These sensors are called the Start of Trace SOT and Start of Scan SOS sensors The SOT sensor controls the total width of the laser scan which is wider than the maximum media width SOS provides the timing reference which starts the active portion of the laser scan across the media Adjusting these two sensors controls the scan width and linearity of the laser marker assembly The sensors are accessed through a small hole in the front of the laser marker assembly Use a 3 32 Allen key for adjustments Operator Side front of Pl
200. sest to the plate media width 3 Adjust the two front edge guides by loosening the screw and moving all the way to the front 4 Open the feed cassette by lifting the back of the lid and sliding forward at the same time Remove the spool assembly Adjust the left hub to match the edge guide position by squeezeing the clip and sliding on the shaft Remove the right hub from the shaft by lifting the clip and sliding it off the shaft Slide the media onto the shaft Slide the right hub onto the shaft by lifting the clip and pushing down on the spool until the spool is tight against the media see Figure QS 1 Insert the loaded spool assembly back into the feed cassette with 12 of media remaining outside the cassette 5 Place the cassette onto the platesetter cassette mounting brackets 6 Feed media through the 1 set of rollers and 2 edge guides 7 Rotate the cassette up and lock into place on the platesetter Be sure the media is not pinched between the cassette and the platesetter 8 From inside the platesetter push the media up through the next edge guides and into the nip of the pinch roller 9 Set the front edge guides up against the media and tighten the screw 10 Gently lower the marker and lock down by pushing the marker lever towards the rear of the platesetter until the lever is horizontal Close the top cover 11 Set the plate width from the control panel setup menu 12 Push the load knob in This will automatically load th
201. setter and remove the front panel 2 Replace the interface PCA as follows a Access the interface PCA from the front of the Platesetter Remove the plastic shield by unscrewing the four nuts and washers holding the shield b Disconnect all cables Note the correct orientation of each cable c Carefully remove the interface PCA by unscrewing the 4 standoffs which attach the inter face PCA to the chassis d Install the new interface PCA in reverse order Replace the front panel Engine Stepper PCA Location The engine stepper PCA is located underneath the right side of the imager mounted on the side of the chassis see Figure 54 1 The engine stepper PCA provides power and control signals to the feed motor capstan motor exit motor and cutter motor Voltages Supplied to the Engine Stepper PCA 24 VDC stepper motor power 5 VDC signal logic 34 SERVICE MANUAL Connector Assignments J1 Cutter stepper motor J2 Exit stepper motor J3 Feed stepper motor J4 Not Used J5 Power in from power supply drawer J6 Not Used J7 Interface PCA Replacing the Engine Stepper PCA 1 Turn off the Platesetter 2 Remove the front panel 3 Access the Engine Stepper PCA from the front of the Platesetter Disconnect the six cables from the engine stepper PCA Note the correct orientation of each cable 4 Carefully remove the Engine Stepper PCA by removing the 4 nuts securing the engine stepper PCA to the chassis
202. site Be sure to follow these procedures in the order presented Before performing these calibration procedures make sure the Platesetter is in its final location and that it has been properly leveled Once set these calibrations should not have to be repeated unless a problem is noticed If any of the orange torque seals on the screws are broken the Platesetter warranty is void Cutter Skew Plates must be cut square in order to avoid problems with image position straightness and registration when mounted on the press The cutter will pivot at the front of the Imager and can be moved toward or away from the capstan roller at the rear of the unit 1 To determine plate cut squareness print either a grid pattern or a solid pattern from the RIP 2 Once the plate has been imaged and processed measure and compare the diagonal distance of opposite corners of the cut plate see Figure I 5 3 If the plate is square within specification skip the remaining steps and go on to the Transport Skew procedure UJ Leading Edge 4 Remove the back cover from the Platesetter Locate the cutter bracket and note the current position of the cutter a reference line will be inscribed on the bracket at the factory 5 Loosen the two 9 64 Allen cap screws If angle A is lt 90 tighten adjustment screw If angle A is gt 90 loosen adjustment screw Note 1 full turn ofthe adjustment screw moves the cutter approximately 020
203. sponding to Control Panel Error Messages This section shows the different error messages which may be displayed on the Platesetter control panel Next to each error message is the cause and the most probable solutions When more than one solution is listed try the first solution first if it does not correct the problem then try the next solution Once the problem is corrected press the ESC key to clear the error message from the display If the solution s listed does not correct the error call your Printware authorized technician to service your Platesetter CAUSE The load knob is not pushed in SOLUTION Push knob in See chapter 3 in the sec tion Loading Plate Media CAUSE The Platesetter is out of media or the me dia not loaded properly SOLUTION See chapter 3 in the section Loading Plate Media media or not loaded far enough 43 OPERATING THE PLATESETTER CAUSE The Guide B sensor is blocked SOLUTION Clear media path See chapter 7 in the section Clearing Media Path CAUSE The leading edge of the media was not detected by the Guide B sensor within the expected amount of time SOLUTION Clear media path See chapter 7 in the section Clearing Media Path Media didn t enter Guide CAUSE The Imager Exit sensor is blocked SOLUTION Clear media path See chapter 7 in the section Clearing Media Path OPERATING THE PLATESETTER CAUSE The leading edge of the m
204. ssages 3 Check for faulty Load switch 3 1 Remove media 3 2 View Sensor Status on Operator Panel 1 means media present 3 3 Manually actuate the Load OK switch Ifit the status does not toggle check the cable by unplugging the Load OK and No Media switches and plugging the Load OK cable into the No Media switch Manually actuate the No Media switch If the Sensor Status does not toggle with the Load OK cable replace the cable Ifthe status does toggle with the Load OK cable the cable is good Replace the switch 4 Ifthe Load OK switch and cable test good but there are still spurious No media or Media not loaded far enough messages bend the Load OK switch lever back toward the left of the machine slightly to increase its sensitivity A Load OK Capstan Roller switch i No Media switch Note this lower arm is present switch dual cassette 46 machines only 2 Imager module sensor locations 55 SERVICE MANUAL GENERAL IMAGER PROBLEMS cont Imaging seems to First plates take longer than other plates General guidelines for take too long first plate total times are as follows Resolution No punch With Punch 900 DPI 2 min 2 min 30 sec 1200 DPI 2 min 30 sec 3 min 1800 DPI 3 min 3 min 30 sec 2400 DPI 3 min 30 sec 4 min Add 30 sec to each time for the PlateStream 46 56 SERVICE MA
205. t separately for each combination of destination see item 6 and resolution see item 1 Thus up to eight image power settings can be stored for the possible combinations of two destinations Processor Miniplate or Cassette and four resolutions This allows a different image power to be set for film in the Cassette mode compared to plate material in the Processor mode for example Optimal image power settings also change with resolution 4 Media Width xx xx Spool Pos yy Media Width is the exact width entered by the operator from 9 00 to 18 10 22 90 cm to 46 00 cm Spool Pos is automatically calculated from Media Width and indicates the position to set the spool or cassette Spool position is set at the media width in inches rounded to the nearest inch from 9 to 18 Media Width is set independently for each of the Input Spools see 5 below eliminating the need to reset image width every time the spool is changed 5 Input Spool Selects the input spool The choices are A B C or D A different default spool can be set for Processor Miniplate and Cassette modes For example Spool A could be set as the default in Processor Miniplate mode to be used for plate material and Spool B as default in Cassette mode to be used for film If the destination is switched back from Cassette to Processor or Miniplate the Input Spool would automatically default back to Spool A The media remaining for the selected cassette decreases as me
206. tire page is the imager exit rollers imaged the media into the integrated advances to the cutter processor The media is cut to a specified plate length and punched 6 eo The plate is developed The finished plates fixed and dried are collected in a basket Figure 1 1 Flowchart of the Platemaker Process GENERAL INFORMATION ASS Host Computer Jobstream character codes plus command codes gt 1 Host Computer External RI File reconfigured commands interpreted Figure 1 2 Interface Between the Host Computer RIP and PlateStream 46 1 3 GENERAL INFORMATION Figure 1 3 illustrates the Platesetter media path It uses a four step photographic process 1 Imaging The laser light beam sweeps across the emulsion side of the plate material as it passes the laser marker unit The data generated by the RIP turns the laser on and off When the laser is turned on the portion of the plate exposed to the laser sweep is imaged black the portions of the media not exposed to the laser remain clear or silver During imaging the Start Of Scan SOS sensor on the marker unit counts the number of scan lines being imaged on the plate at
207. to the optional film cassette sensor located on the left side of the processor Insert wire tray into slots located on the top right side of the Platesetter Attach customer supplied power plug to Platesetter power cord located in the rear of the machine per electrical wiring codes Assembling the Processor NOTE Follow manufacturer s safety instructions for Activator and Stabilizer and do not contaminate the Activator pieces with Stabilizer solution Open the top right cover Remove black tape holding Cover G activator and stabilizer racks Remove the four styrofoam pieces located in the front and rear of the processor working tanks inside the Platesetter Remove bubble pack wrapped around Cover E Guide F overflow tubes and Cover G Place the overflow tubes in the large holes located in the rear of the processor working tanks inside the Platesetter Press down until overflow tubes stop Place the spring pin from Guide F into the hole located in the rear of the activator tank while placing the other pin into the hole located in the rear of the stabilizer tank Slide Guide F towards the rear of the Platesetter while placing pins on the other side of Guide F into the holes located in the front of the activator and stabilizer racks Place the two replenishment tanks on the smaller cart Place the optional effluent tank on the optional larger cart If necessary prepare the Activator and the Stabilizer solutions in the replenishment tanks fo
208. tter until it clears the frame Access lower roller from the hole in the front of the Platesetter Remove the lower roller by sliding towards the rear of the Platesetter until it clears the frame 4 Install the new rollers in reverse order Replace the panels lower the marker and close the top left cover Replacing the Imager Exit Rollers Imager Exit Motors and Imager Exit Belts 1 Open the top cover and raise the marker assembly Remove the back panel 2 Rotate the belt tensioner down and then slide the long imager exit belt off the pulley 3 Remove the bracket holding the pulley by unscrewing the three screws holding the bracket Remove the bracket holding the motor by unscrewing the four screws holding the bracket 4 Rotate the I shaped bracket located behind the pulley 90 and then slide the belts off of the gear 5 To replace belts install new belts in reverse order 6 To replace motor disconnect the cable from the motor Remove the motor from the bracket Install new motor in reverse order Adjust drive belt tension by adjusting set screw on the motor shaft and or pulley shaft 7 To replace rollers remove the pulley from the roller shaft by removing E clip Remove the E clips and spacers if any from each end of the lower shaft Remove the bushings from each end of the roller shaft Access the upper roller from the top of the Platesetter Remove Guide C by pressing down on the four pins Remove the upper roller by sliding
209. tus of all Platesetter sensors Explanation of all the sensor indications are shown below LOAD KNOB This sensor is activated when the load knob is pushed A 0 indicates the knob is pushed in 1 indicates the load knob is pulled out FEED LOOP Indicates the status of the service loop sensor in the feed area of the Platesetter T indicates that a loop is formed 0 indicates that a loop is not present EXIT LOOP Indicates the status of the exit loop sensor in the exit section of the Imager 1 indicates that a loop is formed 0 indicates that a loop is not present IMAGER EXIT Indicates the presence of media at the imager exit A 1 indicates the media is present e g during imaging A 0 means the sensor is clear this is the normal idle condition NO MEDIA Identifies the amount of media in the spool as okay or none A 0 indicates that the media supply is empty 1 indicates that the amount is sufficient LOAD OK Indicates the status of media loading A 1 indicates the media is loaded a 0 indicates the media is not loaded GUIDE B Indicates the presence of media at Guide A 1 indicates that media is present e g during imaging A 0 indicates the sensor is clear This is the normal idle condition WRKNG TANK LOW This sensor monitors the solution level in the working tanks within the processor A 0 indicates the current level is ok
210. ull gauge or fish scale 1 1 Attach a 2 wide 50 mm strip of thin 0 004 or 0 005 0 1 mm polyester media to the gauge Slide the strip between the roller pair to be tested and measure the force required to pull the media strip out of the roller pairs force should be the same from side to side 1 2 Adjust roller tensioner screws on either side of the roller pairs to set correct tension Correct roller tensions are as follows Infeed rollers approx 4 Ibs 18 N First pinch rollers approx 4 5 lbs 20 Second pinch rollers 8 14 lbs 50 note tensioner on operator side may look tighter due to the traction control on the back of this roller Exit rollers approx 4 Ibs 18 N If unable to resolve the problem send sample plates to Printware Send four maximum width grid pattern plates We can measure and advise on adjustments 48 SERVICE MANUAL OPERATOR PANEL PROBLEMS Operator Panel beeps 1 Check voltages at controller PCA continuously after initialization 2 Replace Operator Panel Note The machine is designed to beep continuously every 5 seconds if a job is sent with an unsupported resolution Buttons on Operator Panel don t Re seat cables in J1 and J2 on the Operator Panel work or are touchy 2 Wiggle the Operator Panel cables to determine whether there is a short in a cable 3 Replace Operator Panel assembly Operator Panel blanks out occa 1 Install stati
211. ur PCAs and one power supply assembly within the imager half of the Platesetter These are Controller PCA Interface PCA Engine Stepper PCA Control Panel PCA Power Supply Assembly This chapter provides the following information for each PCA location voltages connector and pin assignments replacement instructions This chapter also includes information about the sensors 28 SERVICE MANUAL NOTE There are no procedures for replacing the SOS and SOT sensors The SOS and SOT sensors are part of the marker assembly and are not replaced separately Controller PCA _Grounding Connector 1 Engine Stepper Interface Power Supply Figure S4 1 Location of the PCAs Controller PCA Location and Function The controller PCA is attached to the top of the marker See Figure 54 1 Controller PCA elec tronics perform the following functions control data transmission from RIP to Platesetter control laser intensity 29 SERVICE MANUAL control laser data rate monitor all sensors control galvo control motors The non volatile SRAM memory of the controller PCA stores the total plate count the image quality settings specified using the Manual Setup menu on the control panel for both polyester and paper plate material the image position settings and the calibration settings V
212. utter to access the roller Remove the roller by sliding the roller towards the rear of the frame until it clears the frame 6 Install the new roller in reverse order Lower marker assembly and close the top cover 22 SERVICE MANUAL Removing the Capstan roller and Capstan Drive Assembly See Figure S3 1 S3 2 Marker v Lever Marker jas NE M Capstan Drive Motor Figure 53 2 Location of the Capstan Drive Motor 1 Open the top cover and raise the marker Remove the front and rear panels 2 Remove the pinch rollers Refer to the previous procedure 3 Access the capstan drive assembly from the front of the Platesetter Remove the bracket covering the capstan drive assembly by unscrewing five screws Disconnect the cable from the capstan drive assembly Remove the capstan drive assembly by removing the three screws holding the bracket Slide the belts off of the capstan roller These screws are located underneath the capstan drive assembly 23 SERVICE MANUAL 4 To replace the belts remove the E clip and bearing from the capstan drive assembly Install the new belts in reverse order 5 To replace the motor remove the three screws holding the motor Install in reverse order 6 To replace the capstan roller remove the shutter assembly located above the capstan roller by removing four screws two on each side attached to the Imager and removing two s
213. warranty issues To locate this bolt Stand in front of the Platesetter operator side facing the Platesetter Open the Imager unit top cover INSTALLATION GUIDE Leading Edge UJ D D 2 D O a O c 9 9 Q O H Figure I 10 No Image Skew diagonal D E diagonal C F e Look down at the point where the laser marker assembly rests on the Imager module metal frame Locate the laser marker assembly Imager cover locking clamps e The adjustment bolt is just to the right toward the Processor module of the right locking clamp 3 Figure I 10 shows no image skew Ifthe image skew condition shown in Figure I 11 is present turn the adjustment screw clockwise to lower the front of the laser marker assembly 4 Ifthe image skew condition shown in Figure I 12 is present turn the adjustment screw counterclock wise to raise the front of the laser marker assembly 5 After each adjustment close the platesetter top cover Run two test plates and measure the second plate for image skew Continue until the image is square on the plate l 18 INSTALLATION GUIDE Leading Edge UJ a SS N Open Cover Laser Marker Assembly Fxedpoint 9 Capstan Roller Media E Frame Rear Side Front Operator Side Operator Side front of Platesetter G DE Figure 1 11 Image Skew Laser marker as

Platestream 46 manual

Contents

Download Pdf Manuals

Related Search

Related Contents